Chrysler Town, Dodge Caravan. Manual — part 311
(4) Remove camshaft sprockets. Hold camshaft
sprocket with Special Tool 6847 while removing cen-
ter bolt (Fig. 112).
(5) Remove timing belt idler pulley (Fig. 113).
(6) Remove rear cover fasteners and remove cover
from engine (Fig. 114).
INSTALLATION
FRONT COVER - UPPER
(1) Install timing belt cover. Torque fasteners to 6
N·m (50 in. lbs.) (Fig. 110).
FRONT COVER - LOWER
(1) Install timing belt front covers (Fig. 110).
Tighten fasteners to 6 N·m (50 in. lbs.).
(2) Install generator drive belt tensioner (Refer to
7
-
COOLING/ACCESSORY
DRIVE/BELT
TEN-
SIONERS - INSTALLATION).
(3) Install crankshaft vibration damper (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
REAR COVER
(1) Install rear timing belt cover and fasteners.
Torque fasteners to specified values (Fig. 114).
CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
Fig. 111 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)
Fig. 112 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 113 Timing Belt Idler Pulley
1 - IDLER PULLEY
2 - BOLT
9 - 62
ENGINE 2.4L
RS
TIMING BELT COVER(S) (Continued)
(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N·m
(75 ft. lbs.) (Fig. 112).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N·m (45 ft. lbs.) (Fig. 113).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(5) Install engine mount bracket and tighten bolts
to 61 N·m (45 ft. lbs.) (Fig. 111).
(6) Install front covers.
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Remove make-up air hose from cylinder head
cover.
(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.
(6) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove air conditioner/generator belt tensioner
and pulley assembly (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL).
(9) Remove timing belt lower front cover bolts and
remove cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(10) Lower vehicle.
(11) Remove bolts attaching timing belt upper
front cover and remove cover (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT
COVER(S)
-
REMOVAL).
(12)
Remove right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).
(13) Remove engine mount bracket (Fig. 115).
Fig. 114 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N·m (105 in. lbs.)
2 - M8 BOLTS - 28 N·m (250 in. lbs.)
3 - TIMING BELT TENSIONER
Fig. 115 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)
RS
ENGINE 2.4L
9 - 63
TIMING BELT COVER(S) (Continued)
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(14) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 116).
NOTE:
The
crankshaft
sprocket
TDC
mark
is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(15) Loosen timing belt tensioner lock bolt (Fig.
117).
(16) Insert a 6 mm Allen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley (Fig. 117). Rotate the top plate CLOCKWISE
until there is enough slack in timing belt to allow for
removal.
(17) Remove timing belt.
CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
REMOVAL - CAMSHAFT SPROCKETS
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Hold camshaft sprockets with Special Tool 6847
while removing center bolts (Fig. 118).
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove
crankshaft
sprocket
using
Special
Tools 6793 and insert C-4685-C2 (Fig. 119).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
Fig. 116 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 117 Timing Belt Tensioner
1 - LOCK BOLT
2 - TOP PLATE
9 - 64
ENGINE 2.4L
RS
TIMING BELT AND SPROCKET(S) (Continued)
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 120).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install
camshaft
sprockets.
Hold
camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N·m (85 ft. lbs.) (Fig. 118).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set
camshafts
timing
marks
so
that
the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 121).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 122).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 122) to align marks and take up belt
slack.
(5) Insert a 6 mm Allen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plate COUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 123). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N·m (220 in. lbs.). Set-
Fig. 118 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 119 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET
Fig. 120 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RS
ENGINE 2.4L
9 - 65
TIMING BELT AND SPROCKET(S) (Continued)
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