300, Magnum, 2005

Timing Chain Cover & Seal

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Removal & Installation



2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove coolant recovery bottle.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove lower splash shield retaining bolts and splash shield.
  12.  
  13. Remove accessory drive belts.

    Click image to see an enlarged view

    Fig. Use special tool 9365 Damper Holder (2) to hold damper (1) while removing attaching bolt (3)-2.7L engine

  14.  
  15. Use special tool 9365 Damper Holder to hold damper while removing attaching bolt.

    Click image to see an enlarged view

    Fig. Remove damper by using Special Tools 8194 Insert (1) and 8454 Puller (2)-2.7L engine

  16.  
  17. Remove damper by using Special Tools 8194 Insert and 8454 Puller.
  18.  
  19. Lower vehicle.

    Click image to see an enlarged view

    Fig. Timing chain cover gasket (1), cover (2), and bolts (3 & 4)-2.7L engine

  20.  
  21. Remove timing chain cover bolts.
  22.  
  23. Remove timing chain cover.
  24.  
  25. Discard timing chain cover gasket.

    Click image to see an enlarged view

    Fig. Install Special Tool 8194 (1), Insert into crankshaft nose to remove the seal-2.7L engine

  26.  
  27. Install Special Tool 8194, insert into crankshaft nose. Remove seal using Special Tool 6771, Remover.
  28.  

To install:

  1. Inspect and clean timing chain cover sealing surfaces.

    Click image to see an enlarged view

    Fig. RTV application points at parting lines between the oil pan and cylinder block-2.7L engine

  2.  
  3. Before installing timing cover gasket apply a 1 / 8 inch bead of Mopar® Engine RTV GEN II, or equivalent, to the parting lines between the oil pan and cylinder block.
  4.  
  5. Install timing cover and gasket. Tighten M10 cover bolts to 40 ft. lbs. (54 Nm) and M6 bolts to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Install new seal (4) using Special Tools 6780-2 Sleeve (1), 6780-1 Installer (3), and 8179 Stud (2)-2.7L engine

  6.  
  7. Install new seal using Special Tools 6780-2 Sleeve, 6780-1 Installer, and 8179 Stud.

    Click image to see an enlarged view

    Fig. Install damper (1) using Special Tools 8179 Screw (3), with Nut and Thrust Bearing from 6792, and 6792-1 Installer (2)-2.7L engine

  8.  
  9. Install damper using Special Tools 8179 Screw, with Nut and Thrust Bearing from 6792, and 6792-1 Installer.
  10.  
  11. Install damper attaching bolt. Use special tool 9365 damper holder to hold damper while tightening attaching bolt to 125 ft. lbs. (170 Nm).
  12.  
  13. Install accessory drive belts.
  14.  
  15. Install lower splash shield and retaining bolts.
  16.  
  17. Lower vehicle.
  18.  
  19. Fill cooling system.
  20.  
  21. Connect negative battery cable.
  22.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove air cleaner assembly.
  8.  
  9. Drain cooling system.
  10.  
  11. Remove accessory drive belt.
  12.  
  13. Disconnect cooling fan electrical connector.
  14.  
  15. Remove cooling fan mounting bolts.
  16.  
  17. Remove radiator cooling fan assembly from vehicle.
  18.  
  19. Remove coolant bottle and washer bottle.
  20.  
  21. Remove fan shroud.
    NOTE
    It is not necessary to disconnect air conditioning lines or discharge refrigerant.

  22.  
  23. Remove air conditioning compressor and set aside.
  24.  
  25. Remove the alternator.
  26.  
  27. Remove upper radiator hose.
  28.  
  29. Disconnect both heater hoses at timing cover.
  30.  
  31. Disconnect lower radiator hose at engine.
  32.  
  33. Remove accessory drive belt tensioner and both idler pulleys.

    Click image to see an enlarged view

    Fig. Removing the damper-5.7L engine

  34.  
  35. Remove crankshaft damper bolt and remove the damper (2) with a puller (1).

    Click image to see an enlarged view

    Fig. Removing the front seal-5.7L engine

  36.  
  37. Using Special Tool 9071 (1), remove crankshaft front seal (2).
    NOTE
    Do not remove the hoses from the power steering pump.

  38.  
  39. Remove power steering pump and set aside.
  40.  
  41. Remove the dipstick support bolt.
  42.  
  43. Drain the engine oil.
  44.  
  45. Remove the oil pan and pick up tube.
    NOTE
    It is not necessary to remove water pump for timing cover removal.

  46.  
  47. Remove timing cover bolts and remove cover.

    Click image to see an enlarged view

    Fig. Timing cover slide bushings in place-5.7L engine

  48.  
  49. Verify that timing cover slide bushings (1) are located in timing cover.
  50.  

To install:

  1. Clean timing chain cover and block surface.
    NOTE
    Always install a new gasket on timing cover.

  2.  
  3. Verify that the slide bushings are installed in timing cover.
  4.  
  5. Install cover and new gasket. Tighten fasteners to 21 ft. lbs. (28 Nm).
    NOTE
    The large lifting stud is torqued to 40 ft. lbs. (55 Nm).

  6.  
  7. Install the oil pan and pick up tube.
  8.  
  9. Install the air conditioning compressor.
  10.  
  11. Install the alternator.
  12.  
  13. Install power steering pump.
  14.  
  15. Install the dipstick support bolt.
  16.  
  17. Install the thermostat housing.
    WARNING
    The front crankshaft seal must be installed dry. Do not apply lubricant to sealing lip or to outer edge.



    Click image to see an enlarged view

    Fig. Front seal installation-5.7L engine

  18.  
  19. Using Special Tool 8348 (1) and 8512A (2), install crankshaft front seal.
    WARNING
    To prevent severe damage to the crankshaft, damper or Special Tool 8512-A, thoroughly clean the damper bore and the crankshaft nose before installing damper.

  20.  
  21. Slide damper onto crankshaft slightly.
    WARNING
    Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft.



    Click image to see an enlarged view

    Fig. Crankshaft damper installation tool-5.7L engine

  22.  
  23. Assemble Special Tool 8512-A as follows, the nut is threaded onto the shaft first (2). Then, the roller bearing (1) is placed onto the threaded rod (3). The hardened bearing surface of the bearing (1) MUST face the nut (2). Then, the hardened washer (5) slides onto the threaded rod (3). Once assembled coat the threaded rod-s threads with Mopar® Nickel Anti-Seize or (Loctite® No. 771).
  24.  
  25. Using Special Tool 8512-A, press damper onto crankshaft.
  26.  
  27. Install then tighten crankshaft damper bolt to 129 ft. lbs. (176 Nm).
  28.  
  29. Install accessory drive belt tensioner assembly and both idler pulleys.
  30.  
  31. Install radiator lower hose.
  32.  
  33. Install both heater hoses.
  34.  
  35. Position radiator cooling fan assembly in vehicle.
  36.  
  37. Install cooling fan mounting bolts. Tighten to 50 inch lbs. (6 Nm)
  38.  
  39. Connect cooling fan electrical connector.
  40.  
  41. Install the fan and fan drive assembly
  42.  
  43. Install the accessory drive belt.
  44.  
  45. Install the coolant bottle and washer bottle.
  46.  
  47. Install the upper radiator hose.
  48.  
  49. Install the air cleaner assembly.
  50.  
  51. Fill cooling system.
  52.  
  53. Refill engine oil.
  54.  
  55. Connect the battery negative cable.
  56.  
  57. Install the engine cover.
  58.  

 
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