Avenger 2008

Timing Chain & Sprockets

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Removal & Installation



2.4L Engine
Camshaft Sprocket

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

See Camshaft Removal and Installation.

Crankshaft Sprocket

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove timing chain.
  2.  
  3. Remove oil pan.
  4.  
  5. Remove oil pump drive chain tensioner.
  6.  
  7. Remove oil pump drive chain.
  8.  
  9. Remove crankshaft sprocket (1).

    Click image to see an enlarged view

    Fig. Remove crankshaft sprocket (1)

  10.  

To install:

  1. Install crankshaft sprocket onto crankshaft.
  2.  
  3. Install oil pump drive chain. Verify that Oil pump is correctly timed (1,2,5,6).

    Click image to see an enlarged view

    Fig. Install oil pump drive chain

  4.  
  5. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514.

    Click image to see an enlarged view

    Fig. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514

  6.  
  7. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4).

    Click image to see an enlarged view

    Fig. Install oil pump drive chain tensioner (3)

  8.  
  9. Install timing chain.
  10.  
  11. Install oil pan.
  12.  
  13. Fill engine with oil.
  14.  
  15. Start engine and check for leaks.
  16.  

Timing Chain

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove timing chain cover.
    NOTE
    The crankshaft timing mark (3) or (5) can be in one of two locations depending on whether the engine is early production (5), late production (3) or assembled with service parts (3). In all cases the keyway (2) will always be in the 9:00 position, in line with the ladder frame mounting surface (1) when the engine is at TDC.



    Click image to see an enlarged view

    Fig. Crankshaft timing chain marks

  2.  
  3. Verify that the engine is still set to TDC.
    NOTE
    If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused.

  4.  
  5. Mark chain link (4) corresponding to crankshaft timing mark (3) or (5).
  6.  
  7. With the engine still set to TDC, verify that the marks on the camshaft sprockets (3) are in line with the cylinder head cover sealing surface (2). If the marks do not line up, the timing chain is not correctly installed.

    Click image to see an enlarged view

    Fig. Verify that the marks on the camshaft sprockets (3) are in line with the cylinder head cover sealing surface (2)

  8.  
  9. Mark chain link (1) corresponding to camshaft timing mark.
  10.  
  11. Remove timing chain tensioner (5).

    Click image to see an enlarged view

    Fig. Remove timing chain tensioner (5)

  12.  
  13. Remove timing chain (2).
  14.  

To install:


NOTE
The crankshaft timing mark can be in one of two locations depending on whether the engine is early production (5), late production (3) or assembled with service parts. In all cases the keyway will always be in the 9:00 position, in line with the ladder frame mounting surface when the engine is at TDC.

  1. Verify that the engine is still set to TDC.
  2.  
  3. Align camshaft timing marks so they are facing each other and in line with the cylinder head cover sealing surface.
  4.  
  5. Install timing chain so plated (or marked) links on chain align with timing marks on camshaft sprockets.
  6.  
  7. Align timing mark on the crankshaft sprocket with the plated (or marked) link on the timing chain. Position chain so slack will be on the tensioner side.
    NOTE
    Keep the slack in the timing chain on the tensioner side.

  8.  
  9. Install the timing chain tensioner.
  10.  
  11. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position.
  12.  
  13. Verify that the camshafts timing marks are in the proper position and in line with the cylinder head cover sealing surface. If the marks do not line up, the timing chain is not correctly installed.
  14.  
  15. Install front timing chain cover.
  16.  
  17. Connect negative battery cable.
  18.  
  19. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct fluid levels.
  20.  

2.7L Engine
Crankshaft Sprocket

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove primary timing chain.
    CAUTION
    Use care not to turn crankshaft while removing crankshaft sprocket, as damage to valves and or pistons could occur.

  2.  
  3. Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equivalent to damper bolt head and position Special Tools 5048-1, 5048-6, and 8539 (1) on sprocket and crankshaft nose. Remove sprocket using care not to rotate the crankshaft.

    Click image to see an enlarged view

    Fig. Apply grease or equivalent to damper bolt head and position Special Tools 5048-1, 5048-6, and 8539 (1) on sprocket and crankshaft nose

  4.  

To install:

  1. Install crankshaft sprocket using Special Tools 6780-1 and 8179 (2) until sprocket bottoms against crankshaft step flange. Use care not to rotate crankshaft.

    Click image to see an enlarged view

    Fig. Install crankshaft sprocket using Special Tools 6780-1 and 8179 (2)

  2.  
  3. Verify that crankshaft sprocket is installed to proper depth by measuring from sprocket outer face to end of crankshaft. Measurement should read: 1.5374 ±0.020 inches (39.05 ±0.50 mm).

    Click image to see an enlarged view

    Fig. Verify that crankshaft sprocket is installed to proper depth by measuring

  4.  
  5. Install primary timing chain.
  6.  

Timing Chain & Camshaft Sprockets

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009



Click image to see an enlarged view

Fig. Exploded view of timing chain components-2.7L engine

  1. Disconnect negative battery cable.
  2.  
  3. Drain cooling system.
  4.  
  5. Remove upper intake manifold.
  6.  
  7. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.
    CAUTION
    When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

  8.  
  9. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 60° ATDC of #1 cylinder.
    CAUTION
    When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.



    Click image to see an enlarged view

    Fig. Align crankshaft sprocket timing mark to mark on oil pump housing (2)

  10.  
  11. Remove power steering pump and bracket as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap.
  12.  
  13. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

    Click image to see an enlarged view

    Fig. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head

  14.  
  15. Disconnect and remove camshaft position sensor from left cylinder head.
  16.  
  17. Remove timing chain guide access plugs from cylinder heads.
    NOTE
    When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

  18.  
  19. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (if equipped) and sprocket.
  20.  
  21. Remove left side camshaft sprocket attaching bolts and remove sprocket.
  22.  
  23. Remove lower chain guide (7) and tensioner arm (8).
  24.  
  25. Remove the primary timing chain.
  26.  
  27. For removal of crankshaft sprocket.
  28.  

To install:

Click image to see an enlarged view

Fig. Timing chain and sprockets assembly

  1. Inspect all sprockets and chain guides (2,9). Replace if worn.
  2.  
  3. For crankshaft sprocket installation procedures.
  4.  
  5. If removed, install right and left side short chain guides (9). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
  6.  
  7. Align crankshaft sprocket timing mark (4) to the mark on oil pump housing.
    NOTE
    Lubricate timing chain and guides with engine oil before installation.

  8.  
  9. Place left side primary chain sprocket onto the chain so that the timing mark is located in between the two (plated) timing links.
  10.  
  11. Lower the primary chain with left side sprocket through the left cylinder head opening.
    NOTE
    The camshaft sprockets can be allowed to float on the camshaft hub during installation.

  12.  
  13. Loosely position left side camshaft sprocket over camshaft hub.
  14.  
  15. Align timing (plated) link to the crankshaft sprocket timing mark (3).
  16.  
  17. Position primary chain onto water pump drive sprocket.
  18.  
  19. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain and loosely position over camshaft hub.
  20.  
  21. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
  22.  
  23. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
    NOTE
    Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

  24.  
  25. Install chain guide access plugs to cylinder heads. Tighten plugs to 15 ft. lbs. (20 Nm).
    NOTE
    To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

  26.  
  27. Purge oil from timing chain tensioner using the following procedure:

    Click image to see an enlarged view

    Fig. Purge oil from timing chain tensioner

    1. Place the check ball end of tensioner into the shallow end of Special Tool 8186.
    2.  
    3. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.
    4.  

  28.  
  29. Reset timing chain tensioner using the following procedure:

    Click image to see an enlarged view

    Fig. Reset timing chain tensioner

    1. Position cylinder plunger into the deeper end of Special Tool 8186 (2).
    2.  
    3. Apply a downward force until tensioner is reset (1).
      NOTE
      If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner check ball.


      CAUTION
      Ensure the tensioner is properly reset. The tensioner body must bottom against the top edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.

    4.  

  30.  
  31. Install the reset chain tensioner into the right cylinder head.
  32.  
  33. Position tensioner retaining plate and tighten bolts to 105 inch lbs. (12 Nm.
  34.  
  35. Starting at the right cylinder bank, first position the camshaft damper (if equipped) on camshaft hub, then insert a 3 / 8 inches square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 21 ft. lbs. (28 Nm).
  36.  
  37. Turn the left side camshaft by inserting a 3 / 8 inches square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 21 ft. lbs. (28 Nm).
  38.  
  39. Rotate engine slightly clockwise to remove timing chain slack, if necessary.
  40.  
  41. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

    Click image to see an enlarged view

    Fig. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm

  42.  
  43. Install power steering pump and bracket assembly.
  44.  
  45. Install camshaft position sensor and connect electrical connector.
  46.  
  47. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
  48.  
  49. Install upper intake manifold.
    NOTE
    After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

  50.  
  51. Fill cooling system.
  52.  
  53. Connect negative battery cable.
  54.  

 
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