Chrysler Pacifica. Manual — part 687

INSPECTION - TIMING BELT

(1) Remove front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).

(2) Inspect both sides of the timing belt. Replace

belt if any of the following conditions exist (Fig. 176):

(a) Hardening of back rubber back side is glossy

without resilience and leaves no indent when
pressed with fingernail.

(b) Cracks on rubber back.
(c) Cracks or peeling of canvas.
(d) Cracks on rib root.
(e) Cracks on belt sides.
(f) Missing teeth.
(g) Abnormal wear of belt sides. The sides are

normal if they are sharp as if cut by a knife.

(h) Vehicle mileage or time at component main-

tenance requirement. (Refer to LUBRICATION &
MAINTENANCE/MAINTENANCE SCHEDULES -
DESCRIPTION)
(3) If none of the above conditions are seen on the

belt, the front timing belt cover can be installed
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).

INSTALLATION

INSTALLATION - CRANKSHAFT SPROCKET

CAUTION: To ensure proper installation depth of
crankshaft sprocket, Special Tool 6641 must be
used.

(1) Install crankshaft sprocket using Special Tools

6641 and C-4685-C1 (Fig. 177).

(2) Install timing belt (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION).

INSTALLATION - CAMSHAFT SPROCKETS

CAUTION: The camshaft sprockets are keyed and
not interchangeable from side to side because of
the camshaft position sensor pick–up.

(1) Install camshaft sprockets onto the camshafts.

Install NEW sprocket attaching bolts into place. The
255 mm (10 in.) bolt is to be installed in the left cam-
shaft and the 213 mm (8 3/8 in.) bolt is to be
installed into the right camshaft. Do not tighten
the bolts; tightened at later step. Camshaft
sprocket mark should be aligned with the marks on
the cover at both sprockets (Fig. 169).

Fig. 176 Timing Belt Inspection

1 - PEELING
2 - TOOTH MISSING AND CANVAS FIBER EXPOSED
3 - RUBBER EXPOSED
4 - CRACKS
5 - PEELING
6 - ROUNDED EDGE
7 - ABNORMAL WEAR (FLUFFY STRAND)

Fig. 177 Crankshaft Sprocket - Installation

1 - INSTALL WITH SPECIAL TOOL 6641 WITH 12mm SCREW
C-4685–C1 AND THRUST BEARING AND WASHER

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ENGINE 3.5L

9 - 103

TIMING BELT AND SPROCKETS (Continued)

(2) Install the right camshaft thrust plate and

seal. Tighten bolts to 28 N·m (250 in. lbs.) (Fig. 178).

(3) Install the timing belt starting first at the

crankshaft sprocket, then to remaining components
in a counterclockwise direction.

(4) Install the belt around the last sprocket. Main-

tain tension on the belt as it is positioned around the
tensioner pulley. Each camshaft sprockets mark
should still be aligned with the rear cover marks
(Fig. 169).

NOTE: For timing belt tensioner reset procedure,
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
AND SPROCKETS - TIMING BELT - REMOVAL).

(5) Hold the tensioner pulley against the belt and

install the reset (pinned) timing belt tensioner into
the housing. Tighten attaching bolts to 28 N·m (250
in. lbs.).

(6) Remove tensioner retaining pin to allow the

tensioner to extend to the pulley bracket.

(7) Using a dial indicator, position the number 1

piston at TDC.

(8) Hold the camshaft sprocket hex with a 36 mm

(1 7/16 in.) wrench and tighten the camshaft bolts to
the following:

• Right side = 102 N·m (75 ft. lbs.) +90° turn

• Left side = 115 N·m (85 ft. lbs.) +90° turn
(9) Remove dial indicator and install spark plug.
(10) Remove Special Tools 6642.
(11) Install cam retainer/thrust plates and O-rings

(Fig. 178).

(12) Install front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).

(13) Install engine assembly (Refer to 9 - ENGINE

- INSTALLATION).

TIMING BELT

CAUTION: If camshafts have moved from the timing
marks, always rotate camshaft towards the direc-
tion nearest to the timing marks (DO NOT TURN
CAMSHAFTS A FULL REVOLUTION OR DAMAGE to
valves and/or pistons could result).

(1) Align the crankshaft sprocket (10) (Fig. 179)

with the TDC mark (9) on oil pump cover.

(2) Align the camshaft sprockets (2, 7) timing ref-

erence marks (1, 8) with the marks on the rear cover.

(3) Install the timing belt starting at the crank-

shaft sprocket (10) going in a counterclockwise direc-
tion. Install the belt around the last sprocket.
Maintain tension on the belt as it is positioned
around the tensioner pulley (11).

NOTE: If the camshaft gears have been removed it
is only necessary to have the camshaft gear retain-
ing bolts installed to a snug torque at this time.

(4)

Holding the tensioner pulley (11) against the

belt, install the tensioner into the housing and
tighten to 28 N·m (250 in. lbs.). Each camshaft
sprocket mark should remain aligned the cover
marks.

(5)

When tensioner is in place pull retaining pin

to allow the tensioner to extend to the pulley bracket.

(6) Rotate crankshaft sprocket 2 revolutions and

check the timing marks on the camshafts and crank-
shaft. The marks should line up within their respec-
tive locations. If marks do not line up, repeat
procedure.

NOTE: If camshaft gears have been removed and
timing is correct, counterhold and tighten the cam-
shaft gears to final torque specification (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).

(7) Install the front timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).

(8) Tighten the rocker arm assemblies and install

the cylinder head covers (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).

(9) Connect negative battery cable.

Fig. 178 CAMSHAFT THRUST PLATE

1 - CAMSHAFT THRUST PLATE
2 - BOLT
3 - O-RING

9 - 104

ENGINE 3.5L

CS

TIMING BELT AND SPROCKETS (Continued)

Fig. 179 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

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ENGINE 3.5L

9 - 105

TIMING BELT AND SPROCKETS (Continued)

TIMING BELT TENSIONER &
PULLEY

REMOVAL

TENSIONER

(1) For timing belt tensioner removal procedure

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - REMOVAL - TIMING
BELT)

REMOVAL - TENSIONER PULLEY ASSEMBLY

(1) Remove the timing belt. (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL - TIMING BELT)

(2) Remove the timing belt tensioner pulley and

bracket assembly by unscrewing the pivot bolt from
the oil pump housing (Fig. 180).

INSPECTION

INSPECTION - TENSIONER

(1) Inspect

hydraulic

tensioner

for

fluid

loss

around the plunger seal (Fig. 181). Replace tensioner
if leaking.

Fig. 180 TENSIONER PULLEY

1 - TENSIONER PULLEY
2 - PIVOT BOLT
3 - TENSIONER BRACKET

Fig. 181 TIMING BELT TENSIONER

1 - PLUNGER (EXTENDED POSITION)
2 - TENSIONER HOUSING

9 - 106

ENGINE 3.5L

CS