Removal & Installation: Removal & Installation Chrysler Pacifica CS

1. Relieve fuel system pressure and disconnect negative battery cable.
2. Remove both cylinder head covers and loosen the rocker arm assemblies.
3. Raise vehicle on hoist.
4. Remove accessory drive belt and tensioner.
5. Remove bolts for power steering pump and move pump aside.
6. Remove right front wheel and accessory drive belt splash shield.
7. Remove crankshaft damper bolt. Using Puller (1023) and Insert (9020-R), remove crankshaft damper. (Scheme 1)
8. Remove the lower front timing belt cover fasteners.
9. Lower vehicle.
10. On Pacifica, perform the following: Support engine with a floor jack. Remove the air cleaner housing. Remove the front engine mount. Disconnect the fuel supply line at the fuel rail. (Scheme 2)
11. On all models, remove the upper timing belt cover bolts and remove front timing belt cover.
12. If timing belt is to be reused, mark belt running direction.
13. Rotate engine clockwise until crankshaft mark aligns with the TDC mark on the oil pump housing, and the camshaft sprocket marks are aligned with the marks on the rear cover. (Scheme 3)
14. Remove the timing belt tensioner, and remove timing belt.

Scheme 1

Scheme 2

Scheme 3

Installation

1. Place tensioner into a vise and slowly compress the plunger. (Scheme 4) Total bleed down of tensioner should take about 5 minutes.
2. When plunger is compressed into the tensioner body, install a pin through the body and plunger to retain plunger in place until tensioner is installed.
3. Align the crankshaft sprocket with the TDC mark on oil pump cover. (Scheme 3)
4. Align the camshaft sprockets timing reference mark with the mark on the rear cover. (Scheme 3)
5. Install the timing belt starting at the crankshaft sprocket going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley.
6. Holding the tensioner pulley against the belt, install the tensioner into the housing and tighten bolts. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000). Each camshaft mark should remain aligned at the rear cover marks. NOTE: If the camshaft gears have been removed, it is only necessary to have camshaft gear retaining bolts installed to a snug torque at this time. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
7. When tensioner is in place, pull retaining pin to allow the tensioner to extend to the pulley bracket.
8. Rotate camshaft sprocket 2 revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. (Scheme 3) If marks do not line up, repeat procedure. NOTE: If camshaft gears have been removed and timing is correct, counterhold and tighten the camshaft gears to final torque specification. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
9. Install front timing cover.
10. On Pacifica, perform the following: Install the upper engine mount. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000). Connect fuel supply line at fuel rail. (Scheme 2) Install air cleaner housing.
11. On all models, use floor jack to raise vehicle.
12. Install crankshaft damper using 5.9" Bolt With Nut (C-4685-C1) and Thrust Bearing (6792), and Installer (6792-1). (Scheme 5)
13. Install power steering pump fasteners. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
14. Install crankshaft damper bolt. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
15. Install accessory drive belt tensioner. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
16. Install accessory drive belt.
17. Install the accessory drive belt splash shield and right front wheel.
18. Lower vehicle.
19. Tighten the rocker arm assemblies and install cylinder head covers. See «TORQUE SPECIFICATIONS»(ref-162132-S19746541462004051700000).
20. Connect negative battery cable.

Scheme 4

Scheme 5