Timing Components: Service and Repair
REMOVAL1. Disconnect the battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use.
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck and lift bottle off of fan shroud.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud.
8. Remove the fan shroud-to-radiator mounting bolts.
9. Remove viscous fan/drive assembly.
10. Remove the accessory drive belt.
11. Remove the cooling fan support/hub from the front of the engine (Fig. 173).
12. Raise the vehicle on hoist.
13. Remove the crankshaft damper (Fig. 174).
14. Lower the vehicle.
15. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing (Fig. 175), taking care not to mar the gasket surfaces.
16. Remove the fuel injection pump.
17. Disconnect the camshaft position sensor connector.
18. Remove the camshaft.
19. Remove the six front oil pan fasteners.
20. Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged.
21. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal.
22. Remove the gear housing and gasket (Fig. 176).
23. Clean the gasket material from the cylinder block and gear housing.
INSTALLATION
1. Inspect the oil pan gasket, if the gasket can be reused, coat both sides with a film of Mopar Silicone Rubber Adhesive Sealant.
2. If the gasket is torn, it can be repaired. Cut the old gasket off even with the front of the cylinder block.
3. Using the old gasket as a pattern, cut the front section of a new gasket to the same size.
4. Clean the sealing surfaces and coat the new gasket on both sides with a film of Mopar Silicone Rubber Adhesive Sealant.
5. Mark and trim 1.59 mm (1/16 inch) off of the bottom of the new gear housing gasket. Only trim the part of the gasket that meets the oil pan.
NOTE: When properly trimmed, the gear housing gasket should be even with the oil pan gasket when installed.
6. Install the new gear housing gasket on the alignment dowels
NOTE: (MP1.25x50) guide pins can be used to assist in aligning the gasket and gear housing. Be sure to remove the guide pins after alignment.
7. Carefully install the gear housing, making sure both gaskets stay in place (Fig. 176).
8. Install and tighten the gear housing bolts to 24 Nm (18 ft. lbs.) torque.
9. Install and tighten the oil pan bolts to 24 Nm (18 ft. lbs.) torque.
10. Install the camshaft. Align the crankshaft, camshaft, and injection pump gear marks as shown in (Fig. 177).
11. If a new housing is installed, the camshaft position sensor must be transferred to the new housing.
12. Connect the camshaft position sensor connector.
13. Install the injection pump.
14. Obtain a seal pilot/installation tool from a crankshaft front seal service kit and install the pilot into the crankshaft front oil seal.
15. Apply a bead of Mopar Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
16. Using the seal pilot to align the cover (Fig. 178), install the cover to the housing and install the bolts. Tighten the bolts to 24 Nm (18 ft. lbs.) torque.
17. Remove the seal pilot.
18. Raise the vehicle.
19. Install the crankshaft damper (Fig. 174).
20. Lower vehicle.
21. Install the fan support/hub assembly (Fig. 173) and tighten bolts to 24 Nm (18 ft. lbs.) torque.
22. Install the accessory drive belt.
23. Install the cooling fan and shroud together.
24. Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
25. Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
26. Install the radiator upper hose and clamps.
27. Add engine oil.
28. Add coolant.
29. Connect the battery cables.
30. Start engine and inspect for leaks.