GrandCaravan 2008

Timing Belt & Sprockets

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Removal & Installation



4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the front timing belt cover. Refer to Timing Belt Front Cover, removal & installation.
  6.  
  7. Mark the belt running direction, if the timing belt is to be reused.
    WARNING
    When aligning the timing marks, always rotate the engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

  8.  
  9. Rotate the engine clockwise until the crankshaft (10) mark aligns with the TDC mark on the oil pump housing (9) and the camshaft sprocket (2, 7) timing marks (1, 8) are aligned with the marks on the rear cover.

    Click image to see an enlarged view

    Fig. Timing belt alignment-4.0L engine

  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the bolt (2) and reposition the oil cooler hose (1).
  14.  
  15. Remove the timing belt tensioner (12).
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the timing belt (4).
  20.  
  21. Inspect the tensioner for fluid leakage.
  22.  
  23. Inspect the pivot and bolt for free movement, bearing grease leakage, and smooth rotation. If it is not rotating freely, replace the arm and pulley assembly.
    NOTE
    When the tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body.

  24.  
  25. Index the tensioner in a vise the same way it is installed on the engine. This ensures the proper pin orientation when the tensioner is installed on the engine.
    1. Place the tensioner into a vise (1) and SLOWLY compress the plunger. The total bleed down of the tensioner should take approximately 2 minutes.
    2.  
    3. When the plunger is compressed into the tensioner body, install a pin (2) through the body and the plunger to retain the plunger in place until the tensioner is installed.

      Click image to see an enlarged view

      Fig. Timing belt tensioner compression-4.0L engine

    4.  

  26.  
  27. Counter-hold the left cam gear and remove the cam gear retaining bolt.
  28.  
  29. Remove the cam gear.

    Click image to see an enlarged view

    Fig. Camshaft gear removal LH-4.0L engine

  30.  
  31. Counter-hold the right cam gear and remove the cam gear retaining bolt.
  32.  
  33. Remove the cam gear.

    Click image to see an enlarged view

    Fig. Camshaft gear removal RH-4.0L engine

  34.  
  35. Remove the crankshaft sprocket using Gear Puller L-4407-A (1).
  36.  

To install:

  1. Install the crankshaft sprocket using Forcing Screw C-4685-C1, with the Nut and Thrust Bearing from 6792, and Sprocket Installer 6641 (1).
    NOTE
    The camshaft sprockets are keyed and are not interchangeable from side to side because of the camshaft position sensor pick-up.

  2.  
  3. Install a NEW sprocket attaching bolt into place. The 10 inch (255mm) bolt is to be installed in the left camshaft and the 8 3 / 8 inch (213mm) bolt is to be installed into the right camshaft. Counter-hold the camshaft sprocket and tighten the camshaft sprocket bolt to 75 ft. lbs. (102 Nm), plus a 90° turn.
    WARNING
    If the camshafts have moved from the timing marks, always rotate the camshaft towards the direction nearest to the timing marks (DO NOT TURN THE CAMSHAFTS A FULL REVOLUTION OR DAMAGE to the valves and/or pistons could result).

  4.  
  5. Rotate the right camshaft gear (2) to align its timing mark (1). Verify that the left camshaft gear (7) timing mark (8) and the crankshaft gear (10) timing mark (9) are still aligned.

    Click image to see an enlarged view

    Fig. Timing belt alignment-4.0L engine

  6.  
  7. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
  8.  
  9. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten the 2 bolts to 250 inch lbs. (28 Nm). Each camshaft sprocket mark should remain aligned with the cover marks.
  10.  
  11. When the tensioner is in place, pull the retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
  12.  
  13. Rotate the crankshaft sprocket 2 revolutions and check the timing marks on the camshafts and the crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.
    NOTE
    With the camshaft gears in these positions, the lobes are in a neutral position (no load to the valve).

  14.  
  15. Install the front timing belt cover. Refer to Timing Belt Front Cover, removal & installation.
  16.  
  17. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (5 Nm).
  18.  

 
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