Engine Timing Cover(s) - Installation

INSTALLATION






1. If removed, install the coolant outlet housing (1) to the timing cover with a new gasket using only the four bolts (2) shown tightened to 12 Nm (106 in. lbs.).

2. If removed, install the water pump (3) to the timing cover using only the four bolts (4) shown tightened to 12 Nm (106 in. lbs.) Water Pump - Installation.





3. Install the coolant outlet housing gasket (1), the water pump gasket (2) and the O-ring (3).





4. Clean the engine timing cover, cylinder head and block mating surfaces with isopropyl alcohol in preparation for sealant application.

CAUTION:
Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar(R) Threebond Engine RTV Sealant may result in engine fluid leakage.

CAUTION:
Following the application of Mopar(R) Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

5. Apply a 2 to 3 mm wide bead of Mopar(R) Threebond Engine RTV Sealant to the front cover as shown in the following locations:

- Two cylinder head bosses (1)

- Right and left flanges (2)

- Four cylinder head to engine block T-joints (3)

- Cover to right cam chain tensioner gap (4)





6. Align the locator pins (2) on the engine block to the engine timing cover and install the cover.

7. Install and tighten the twenty-two highlighted M6 bolts (1) to 12 Nm (106 in. lbs.).





8. Install the upper (1) and lower oil pans Engine Oil Pan - Installation.





9. Install the right and left cylinder head covers Cylinder Head Cover(s) - Installation.





10. Install the upper intake manifold Removal and Replacement.





11. Install the crankshaft vibration damper (5) Vibration Damper - Installation.





12. Install the generator Service and Repair.





13. Install the accessory idler pulleys (2) Accessory Drive Idler Pulley - Installation.

14. Install the accessory drive belt tensioner (6) Accessory Drive Belt Tensioner - Installation.

15. Install the accessory drive belt (1) Service and Repair.





16. Install the heater core tube assembly to the right upper intake manifold support bracket with two nuts (3) tightened to 12 Nm (106 in. lbs.).





17. Connect the heater core supply hose (1) to the coolant outlet housing.

18. Connect the heater core return hose (2) to the engine coolant pump housing.

19. Install the lower radiator hose (3) to the engine coolant pump housing.







20. Install the thermostat housing (1) and upper radiator hose (2)





21. Install the vacuum pump Installation.






22. Install the air intake resonator assembly Installation.

23. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair

24. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).

25. Fill the cooling system Service and Repair.

26. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair