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Timing Chain Cover: Installation

Fig 1: Rotating Crankshaft To 40° ATDC
GC0034412Courtesy of DAIMLERCHRYSLER CORP.
  1. Be sure valve timing is still locked at 40° ATDC (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
    Fig 2: Applying Sealer
    GC0034506Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Apply sealer ONLY to the area marked (1) as shown. If porous points are visible at the cylinder heads or at the rear of the engine near the sealing surface of the cylinder head gasket, apply sealant at these points. The sealant must be applied only as a 2.0 mm +/- 0.5 mm bead, assembled within 10 minutes, and not be flattened or spread.
  2. Apply a 1.5 to 2.0 mm bead of Loctite 5900 or equivalent sealer to the area marked (1) as shown.
  3. Position the timing chain cover on the front of the engine.
    Fig 3: Locating Timing Chain Cover Bolts
    GC0034505Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly.
  4. Install the timing chain cover bolts and tighten to 20 N.m (15 ft. lbs.).
    Fig 4: Removing/Installing Timing Chain Tensioner
    GC0034416Courtesy of DAIMLERCHRYSLER CORP.
  5. Install the timing chain tensioner (1). Tighten to 80 N.m (59 ft. lbs.) (Refer to ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - INSTALLATION) .
    Fig 5: Removing/Installing Special Tool 9102
    GC0033947Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
  7. Install the starter (Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION) .
  8. Install the upper oil pan (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION) .
  9. Install the lower oil pan (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION) .
  10. Install the generator. (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
    NOTE: Apply a thin coat of lubricant to head bolt threads before installing.
  11. Install the front cylinder head to timing chain cover bolts. Tighten bolts to 20 N.m (7-15 ft. lbs.).
  12. Install the cylinder head covers (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) .
  13. Install the AIR pump.
    Fig 6: Identifying Pressure & Return Lines
    GC0034392Courtesy of DAIMLERCHRYSLER CORP.
  14. Install the power steering pump, return hose (1), and pressure hose (2) (Refer to STEERING/PUMP - INSTALLATION) .
  15. Install the lower radiator and heater hoses to the water pump.
  16. Install the vibration damper (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) .
  17. Install the idler pulley. (Refer to COOLING/ACCESSORY DRIVE/IDLER PULLEY - INSTALLATION) .
  18. Install the accessory drive belt tensioner (Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION) .
  19. Install the accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  20. Install the radiator fan (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  21. Install the engine cover (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) .
  22. Refill all engine fluids to specifications.
  23. Connect the negative battery cable.
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