Chrysler Pacifica. Manual — part 686
INSTALLATION
(1) Clean rear timing belt cover O-ring sealing sur-
faces and grooves (Fig. 168). Lubricate new O-rings
with Mopar
t Dielectric Grease or equivalent to facil-
itate assembly.
(2) Position NEW O-rings on cover (Fig. 168).
(3) Install
rear
timing
belt
cover
(Fig.
167).
Tighten bolts to the following specified torque:
• M10—54 N·m (40 ft. lbs.)
• M8—28 N·m (20 ft. lbs.)
• M6—12 N·m (105 in. lbs.)
(4) Install
camshaft
sprockets
(Refer
to
9
-
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(5) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
TIMING BELT AND
SPROCKETS
REMOVAL
REMOVAL - TIMING BELT
TIMING VERIFICATION
Remove the outer timing covers. Rotate the crank-
shaft until the pointer on the crankshaft sprocket
aligns the TDC mark on the oil pump. Check to
determine if the camshaft sprocket timing marks are
aligned with the marks on the inner timing cover. It
may take an additional full revolution of the crank-
shaft before the camshaft sprocket marks are aligned
(Fig. 169).
CAUTION: The 3.5L is NOT a freewheeling engine.
Therefore, loosen the valve train rocker assemblies
before servicing the timing drive.
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove both cylinder head covers and loosen
the rocker arm assemblies.
(4) Remove the front timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Mark belt running direction, if timing belt is to
be reused.
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
(6) Rotate engine clockwise until crankshaft mark
aligns with the TDC mark on oil pump housing and
the camshaft sprocket timing marks are aligned with
the marks on the rear cover (Fig. 169)
(7) Remove the timing belt tensioner (Fig. 169)
and remove timing belt.
(8) Inspect the tensioner for fluid leakage.
(9) Inspect the pivot and bolt for free movement,
bearing grease leakage, and smooth rotation. If not
rotating freely, replace the arm and pulley assembly.
(10) When tensioner is removed from the engine it
is necessary to compress the plunger into the ten-
sioner body.
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This ensures
proper pin orientation when tensioner is installed
on the engine.
(a) Place the tensioner into a vise and SLOWLY
compress the plunger (Fig. 170). Total bleed down
of tensioner should take about 5 minutes.
(b) When plunger is compressed into the ten-
sioner body install a pin through the body and
plunger to retain plunger in place until tensioner
is installed.
Fig. 168 Rear Timing Belt Cover Seals
1 - REAR TIMING BELT COVER SEALS
2 - REAR TIMING BELT COVER
CS
ENGINE 3.5L
9 - 99
REAR TIMING BELT COVER (Continued)
REMOVAL - CAMSHAFT SPROCKETS
CAUTION: The 3.5L engine is NOT a free-wheeling
design. Therefore, care should be taken not to
rotate the camshafts or crankshaft with the timing
belt removed.
NOTE: The camshaft timing gears are keyed to the
camshaft.
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Remove front timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Position crankshaft sprocket to the TDC mark
on the oil pump housing by turning crankshaft in the
clockwise direction
(4) Install a dial indicator in number 1 cylinder to
check TDC of the piston. Rotate the crankshaft until
the piston is at exactly TDC.
Fig. 169 TIMING GEAR MARKS
1 - RIGHT CAMSHAFT GEAR ALIGNMENT MARK
7 - LEFT CAMSHAFT GEAR
2 - RIGHT CAMSHAFT GEAR
8 - LEFT CAMSHAFT GEAR ALIGNMENT MARK
3 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS -
RIGHT
9 - CRANKSHAFT GEAR ALIGNMENT MARK
4 - TIMING BELT
10 - CRANKSHAFT GEAR
5 - WATER PUMP PULLEY
11 - TIMING BELT TENSIONER PULLEY
6 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS -
LEFT
12 - TIMING BELT TENSIONER
Fig. 170 Compressing Timing Belt Tensioner
1 - VISE
2 - LOCKING PIN
9 - 100
ENGINE 3.5L
CS
TIMING BELT AND SPROCKETS (Continued)
(5) Remove camshaft retainer/thrust plate from
rear of right cylinder head (Fig. 171).
(6) Remove the right cylinder head cover.
(7) Remove the right rocker arm assembly.
(8) Remove the timing belt tensioner and timing
belt.
CAUTION: The right camshaft must be pushed rear-
ward approximately 3 1/2 inches to remove the
camshaft gear retaining bolt and gear. Care must be
taken not to scratch or nick the camshaft or cylin-
der head journals when moving camshaft.
(9) Hold camshaft sprockets with 36 mm (1 7/16
in.) box end wrench.
(10) Loosen and remove the camshaft gear retain-
ing bolt and washer. The right bolt is 213 mm (8 3/8
in.) long and the left bolt is 255 mm (10.0 in.) long.
NOTE: The camshaft timing gears are keyed to the
camshaft.
(11) Remove the camshaft sprockets (Fig. 172),
(Fig. 173).
Fig. 171 CAMSHAFT THRUST PLATE
1 - CAMSHAFT THRUST PLATE
2 - BOLT
3 - O-RING
Fig. 172 LEFT CAMSHAFT SPROCKET
Fig. 173 RIGHT CAMSHAFT SPROCKET
CS
ENGINE 3.5L
9 - 101
TIMING BELT AND SPROCKETS (Continued)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(2) Remove crankshaft sprocket using Special Tool
L-4407-A (Fig. 174).
INSPECTION
TIMING VERIFICATION
Remove the outer timing covers. Rotate the crank-
shaft until the pointer on the crankshaft sprocket
(10) (Fig. 175) aligns the TDC mark on the oil pump
(9). Check to determine if the camshaft sprocket (2,
7) timing marks (1, 8) are aligned with the marks on
the inner timing cover. It may take an additional full
revolution of the crankshaft before the camshaft
sprocket marks are aligned.
Fig. 174 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL L-4407–A
Fig. 175 TIMING GEAR MARKS
1 - RIGHT CAMSHAFT GEAR ALIGNMENT MARK
7 - LEFT CAMSHAFT GEAR
2 - RIGHT CAMSHAFT GEAR
8 - LEFT CAMSHAFT GEAR ALIGNMENT MARK
3 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - RIGHT
9 - CRANKSHAFT GEAR ALIGNMENT MARK
4 - TIMING BELT
10 - CRANKSHAFT GEAR
5 - WATER PUMP PULLEY
11 - TIMING BELT TENSIONER PULLEY
6 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - LEFT
12 - TIMING BELT TENSIONER
9 - 102
ENGINE 3.5L
CS
TIMING BELT AND SPROCKETS (Continued)
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