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1. Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1 . Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation. 3. Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. NOTE: Camshaft sprocket dowel pins will be in 12 o’clock position when timing marks are correctly aligned. 4. Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or Fig. 3 . Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1 . 5. Remove plug from left side of cylinder block. Install a .31″ (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4 . Screwdriver must go in at least 2.36″ (60 mm) or more. If screwdriver will only go in about .79-.98″ (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6. To remove timing belt “B” (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7. Remove crankshaft sensing blade (if equipped). See Fig. 5 . Loosen timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of belt rotation for reassembly reference. Remove timing belt “B”.

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Drive Belt, Serpentine NOTE: Minor cracks in the V-grooved portion of the serpentine drive belt are considered normal and acceptable. If the drive belt (8620) has chunks missing from the ribs, the drive belt should be replaced. NOTE: When installing drive belts on pulley, make sure that all V-grooves make proper contact with pulleys. Conditions requiring drive belt replacement are excessive wear, rib chunkout, severe glazing, frayed cords, etc. Replace any drive belt that exhibits any of these conditions. Removal 1. WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP. Using a 15 mm socket or wrench on bolt, attach drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys. Pulley Routing, Accessory Drive Belt — 3.8L Engine Installation 1. Install drive belt over all pulleys (except drive belt tensioner). 2. Rotate drive belt tensioner as described under Removal to install drive belt over drive belt tensioner pulley. Make sure that all V-grooves make proper contact with pulleys.

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WATER PUMP DRIVE BELT 1. Verify that the water pump drive belt auto tensioner indicator mark does not exceeds the limit. ? If it exceeds the limit, replace the water pump drive belt. (See WATER PUMP DRIVE BELT .) Fig. 21: Water Pump Drive Belt Auto Tensioner Limit Indicator Mark – Malfunction/Worn Belt WATER PUMP DRIVE BELT 1. Remove the plug hole plate. 2. Rotate the water pump drive belt auto tensioner counterclockwise to release the drive belt tension and remove the water pump drive belt. Fig. 23: Locating Water Pump Drive Belt Auto Tensioner 3. Reinstall the water pump drive belt or install a new water pump drive belt. WATER PUMP DRIVE BELT PULLEY REMOVAL NOTE 1. Replace part A of the SST [303-009 (49 UN30 3009)] with the SST [303-457 (49 UN30 3457)]. Fig. 31: Water Pump Pulley Removal Special Tools 2. Remove the water pump pulley using the SSTs.

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SERPENTINE BELT SLIPS OFF IDLER PULLEY Model(s): 1996-1999 Chrysler (NS) Town & Country 1996-1999 Dodge (NS) Caravan 1996-1999 Plymouth (NS) Voyager 1996-1999 Chrysler (GS) Voyager (International Market) SYMPTOM/CONDITION Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt off of the idler pulley. DIAGNOSIS Visually inspect the serpentine belt and idler pulley to determine if mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Fig. 1 ) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Fig. 2 , perform the REPAIR PROCEDURE . REPAIR PROCEDURE This repair is compatible with DaimlerChrysler’s Mobile Service Program and does not require hoists or other full service facility special equipment. 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Fig. 3 ). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Fig. 4 ). 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Fig. 3 ). 7. Remove the engine mounting bracket. 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 N.m (30-50 ft-lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 N.m (30-50 ft-lbs.). 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 N.m (50 ft-lbs.), vertical fastener 102 N.m (75 ft-lbs.), and horizontal fastener 150 N.m (111 ft-lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Fig. 1 ).

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NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. NOTE: The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. REMOVAL 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle.