Chrysler Town, Dodge Caravan. Manual — part 1101
INSTALLATION
(1) Before installation of the balance shaft assem-
bly, the # 1 cylinder must be brought to TDC. Using
special tool VM.1051, roll engine over by hand until
tool can be inserted into engine block locking fly-
wheel from turning (Fig. 87). Once the # 1 cylinder is
brought to TDC, the balance shaft assembly can be
installed.
(2) With balance shaft assembly on work bench.
Insert special tool VM.1056 into balance shaft assem-
bly (Fig. 88). This will ensure proper balance shaft
and crankshaft timing after assembly.
(3) Install balance shaft assembly and retaining
bolts (Fig. 86). Torque bolts to 32.4N·m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT COVER
REMOVAL
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
Fig. 87 TDC ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 88 BALANCE SHAFT ALIGNMENT PIN VM.1056
1 - VM.1056
2 - BALANCE SHAFT ASSEMBLY
RG
ENGINE
9 - 57
BALANCE SHAFT (Continued)
(7) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 89).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(10) Remove timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT
IDLER
PULLEY - REMOVAL).
(11) Using special tool VM.1055, remove camshaft
sprockets (Fig. 90).
(12) Remove timing belt tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TMNG
BELT/CHAIN
TENSIONER&PULLEY - REMOVAL).
(13) Remove injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(14) Remove timing belt inner cover retaining bolts
and remove cover (Fig. 91).
Fig. 89 TIMING BELT COVER (OUTER)
1 - SEAL
2 - TIMING BELT OUTER COVER
3 - RETAINING BOLTS
Fig. 90 CAMSHAFT SPROCKET REMOVAL/
INSTALLATION
1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
3 - IDLER PULLEYS
4 - CAMSHAFT SPROCKET
5 - VM.1055
9 - 58
ENGINE
RG
TIMING BELT COVER (Continued)
INSTALLATION
INSTALLATION - TIMING BELT OUTER COVER
(1) Install timing belt outer cover seal and cover
(Fig. 89). Torque 3mm bolts to 10.8N·m and 8mm
bolts to 10.8N·m.
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Install right engine mount.
(6) Install air cleaner housing.
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Connect negative battery cable.
INSTALLATION - TIMING BELT INNER COVER
(1) Install timing belt inner cover to engine front
cover seal (Fig. 91).
(2) Install timing belt inner cover to cylinder head
cover gaskets (Fig. 91).
(3) Install timing belt inner cover and retaining
bolts (Fig. 91). Torque 10mm bolts to 47.1N·m and
8mm bolts to 10.8N·m.
(4) Install injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install camshaft sprockets (Fig. 90). Torque
bolts to 108N·m.
(6) Install timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT
IDLER
PULLEY - INSTALLATION).
(7) Install timing belt and tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install right engine mount assembly.
(13) Install air cleaner housing.
(14) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(15) Connect negative battery cable.
TIMING BELT IDLER PULLEY
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support
engine
and
remove
right
engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
Fig. 91 TIMING BELT COVER - INNER
1 - TIMING BELT COVER TO CYLINDER HEAD COVER GASKET
2 - TIMING BELT COVER TO FRONT ENGINE COVER SEAL
3 - RUBBER GROMMET
4 - BUSHING
5 - TIMING BELT COVER - INNER
6 - RETAINING BOLT
7 - RETAINING BOLT
8 - RETAINING BOLT
9 - BUSHING
10 - RUBBER GROMMET
RG
ENGINE
9 - 59
TIMING BELT COVER (Continued)
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
NOTE: Idler pulley retaining bolts are LHD thread.
(10) Remove timing belt idler pulleys (Fig. 92).
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 92).
Torque bolts to 47.1N·m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
CAUTION: INSPECT THE TOOTHED BELT, PULLEYS
AND BEARINGS FOR DAMAGE, SEIZURE AND
LEAKS.
NOTE: DO NOT expose the toothed belt to oil,
grease or water contamination. DO NOT clean belt,
pulleys or tensioner with solvent. DO NOT crimp
the timing belt at a sharp angle. DO NOT install belt
with levered tools forcing the belt onto the pulleys.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support
engine
and
remove
right
engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove
vibration
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 92 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
9 - 60
ENGINE
RG
TIMING BELT IDLER PULLEY (Continued)
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