Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 302
(5) Turn crankshaft until number one cylinder is at
Top Dead Center (TDC). The timing marks on the
chain sprocket should line up with the parting line on
the left side of number one main bearing cap. (Fig. 21).
(6) Place chain over crankshaft sprocket so that the
nickel plated link of the chain is over the timing mark
on the crankshaft sprocket (Fig. 21).
(7) Place balance shaft sprocket into the timing
chain (Fig. 17) so that the timing mark on the sprocket
(yellow dot) mates with the (lower) nickel plated link
on the chain
(8) With balance shaft keyways pointing up 12
o’clock) slide the balance shaft sprocket onto the nose of
the balance shaft. The balance shaft may have to be
pushed in slightly to allow for clearance.
THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE AR-
ROW ON THE SIDE OF THE GEAR COVER
SHOULD
LINE
UP
WHEN
THE
BALANCE
SHAFTS ARE TIMED CORRECTLY.
(9) If the sprockets are timed correctly install the
balance shaft bolts and tighten to 28 N
Im (250 in. lbs.).
A wood block placed between crankcase and crankshaft
counterbalance will prevent crankshaft and gear rota-
tion.
CHAIN TENSIONING
(1) Install chain tensioner loosely assembled.
(2) Position guide on double ended stud making sure
tab on the guide fits into slot on the gear cover. Install
and tighten nut/washer assembly to 12 N
Im (105 in.
lbs.).
(3) Place a shim 1mm (.039 inch) thick x 70mm (2.75
inch) long or between tensioner and chain. Push ten-
sioner and shim up against the chain.Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the ad-
justment slot to take up all slack (chain must have
shoe radius contact as shown in Fig. 22).
(4) With the load applied, tighten top tensioner bolt
first, then bottom pivot bolt. Tighten bolts to 12 N
Im
(105 in. lbs.), Remove shim.
(5) Install carrier covers and tighten screws to 12
N
Im (105 in. lbs.).
INTERMEDIATE SHAFT SERVICE
REMOVAL
CAUTION: The oil pump and distributor must be
removed before attempting to remove intermediate
shaft.
(1) Hold sprocket with Tool C-4687 and adaptor Tool
C-4687-1 when removing or installing screw (Fig. 23).
(2) See Timing System and Seals for intermediate
seal removal and replacement.
(3) Remove retainer screws (Fig. 24).
(4) Remove retainer and lay aside.
(5) Remove intermediate shaft.
Fig. 21 Balance Shaft Timing
Fig. 22 Chain Tension Adjustment
.
2.5L ENGINE
9 - 39
INSTALLATION
(1) Lubricate distributor drive gear when installing.
(2) Apply Mopar Gasket Maker as shown in (Fig. 25)
and install intermediate shaft retainer.
(3) Install retaining screws and torque to 12 N
Im
(105 in. lbs.).
INTERMEDIATE SHAFT BUSHING SERVICE
(1) Remove
front
bushing
using
Special
Tool
C-4697-2 with Special Tool Handle C-4171 (Fig. 26).
(2) Install front bushing using Special Tool C-4697-1
and Special Tool Handle C-4171 until tool is flush with
block.
(3) Remove
rear
bushing
using
Special
Tool
C-4686-2 and Special Tool Handle C-4171 (Fig. 27).
(4) Install rear bushing using Special Tool C-4686-1
and Special Tool Handle C-4171 until tool is flush with
block.
Fig. 25 Intermediate Shaft Retainer Sealing
Fig. 26 Intermediate Shaft Bushing, Front
Fig. 27 Intermediate Shaft Bushing—Rear
Fig. 28 Intermediate Shaft Journal Specifications
Fig. 23 Removing/Installing Intermediate
Shaft Sprocket
Fig. 24 Intermediate Shaft Retainer
9 - 40
2.5L ENGINE
.
ENGINE LUBRICATION SYSTEM
Fig. 1 Engine Lubrication System
.
2.5L ENGINE
9 - 41
Fig. 2 Engine Lubrication Components
9 - 42
2.5L ENGINE
.
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