Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Timing Chain Cover and Seal

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2.5L Premier Engine

See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: The crankshaft oil seal is mounted behind the vibration damper in the crankshaft hole bore in the timing chain case cover



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Fig. Fig. 2: Use a timing case cover aligning tool (Tool 6139 or equivalent) to position the timing chain case cover properly during installation

A timing chain cover aligning tool and oil seal removal/installation driver are necessary to complete this procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts. For more information, refer to Routine Maintenance .
  4.  
  5. Remove the engine fan, as described earlier in this section.
  6.  
  7. Remove the crankshaft damper, pulley and key, as described earlier in this section.
  8.  
  9. Remove the alternator and bracket. For more information, refer to Engine Electrical .
  10.  
  11. If equipped with air conditioning, remove the A/C compressor. For more information, refer to Chassis Electrical .
  12.  
  13. Remove the oil pan-to-timing chain cover bolts and the timing chain cover-to-engine block bolts.
  14.  
  15. Remove the front cover assembly from the engine.
  16.  
  17. Cut off the oil pan side gasket end tabs flush with the front face of the cylinder block and remove the gasket tabs.
  18.  
  19. Remove the oil seal from the timing cover by prying it out with a large prytool. Be careful no to damage the front cover seal surface.
  20.  
  21. Clean all gasket material from the sealing surface.
  22.  

To install:
  1. Install the replacement seal so that the open end of the seal is toward the inside of the cover. Support the cover at the seal area while installing the oil seal and drive it into place with a seal installation tool, such as Chrysler Tool 6139.
  2.  

The oil seal can also be installed after the cover has been installed on the engine block, depending upon which of the timing case cover aligning tools are available.

  1. Apply sealant to both sides of the gasket and install on the cover sealing surface.
  2.  
  3. Cut the end tabs from the replacement oil pan side gasket and cement the tabs on the oil pan.
  4.  
  5. Coat the front cover seal end tab recesses with RTV sealant and position the seal on the cover bottom.
  6.  
  7. Position the timing chain cover on the engine block and position an alignment tool into the crankshaft opening.
  8.  

Two different types of alignment tools are available, without seal in housing or with seal in housing.

  1. Install the cover-to-engine block bolts and the oil pan-to-cover bolts. Tighten the cover-to-engine block bolts to 60 inch lbs. (7 Nm) and the oil pan-to-cover bolts to 134 inch lbs. (15 Nm).
  2.  
  3. If not already done, install the oil seal.
  4.  
  5. Install the crankshaft damper and pulley.
  6.  
  7. Install the A/C compressor, alternator and alternator bracket.
  8.  
  9. Install the engine cooling fan.
  10.  
  11. Install and adjust the accessory drive belts, as described in Routine Maintenance .
  12.  
  13. Connect the negative battery cable, start the engine and check for leaks.
  14.  

OIL SEAL REPLACEMENT WITH TIMING CASE COVER INSTALLED

See Figures 3 and 4

Click image to see an enlarged view

Fig. Fig. 3: When the timing chain case cover is installed on the engine, the use of an oil seal removal tool is necessary to prevent damage to the cover



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Fig. Fig. 4: To properly install a new oil seal, use Timing Case Cover Alignment and Seal Installation Tool 6139

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts. For more information, refer to Routine Maintenance .
  4.  
  5. Remove the vibration damper, as described earlier in this section.
  6.  
  7. Remove the fan shroud assembly, as described under the radiator removal and installation procedure earlier in this section.
  8.  
  9. Using an oil seal remover tool, as shown in the accompanying illustration, remove the oil seal from the timing case cover.
  10.  
  11. Clean the oil seal mounting bore of all grime, oil and dirt.
  12.  

To install:
  1. Position the replacement oil seal on the Timing Case Cover Alignment and Seal Installation Tool 6139, or equivalent, with the seal lip facing outward. Apply a light film of Perfect Seal®, or equivalent, on the outside diameter of the seal. Lightly coat the crankshaft with engine oil.
  2.  
  3. The position the tool and seal over the end of the crankshaft and insert a draw screw tool into the seal installation tool 6139. Tighten the nut against the tool until it contacts the cover.
  4.  
  5. Remove the tools. Apply a light film of engine oil on the vibration damper hub contact surface of the seal.
  6.  
  7. With the key inserted in the keyway of the crankshaft, install the vibration damper, washer and bolt. Lubricate and tighten the bolt to 80 ft. lbs. (108 Nm).
  8.  
  9. Install the accessory drive belts.
  10.  
  11. Connect the negative battery cable.
  12.  

2.6L Engine

See Figures 5 and 6

Click image to see an enlarged view

Fig. Fig. 5: Before removing the timing chain case cover, the engine mounting plate must be removed



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Fig. Fig. 6: Exploded view of the timing chain case cover and = fasteners

All 2.6 engines are equipped with 2 balance shafts which cancel the vertical vibrating force of the engine and the secondary vibrating forces, which include the sideways rocking of the engine due to the turning direction of the crankshaft and other rolling parts. The shafts are driven by a duplex chain and are turned by the crankshaft. The silent shaft chain assembly is mounted in front of the timing chain assembly and must be removed to service the timing chain.

  1. Disconnect the negative battery cable.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Drain the radiator and remove it from the vehicle.
  6.  
  7. Remove the cylinder head, as described earlier in this section.
  8.  
  9. Remove the cooling fan, spacer, water pump pulley and accessory drive belts.
  10.  
  11. Remove the alternator. For more information, refer to Engine Electrical .
  12.  
  13. Remove the water pump, as described earlier in this section.
  14.  
  15. Remove the oil pan and screen, as described earlier in this section.
  16.  
  17. Remove the crankshaft pulley.
  18.  
  19. Remove the bolts holding the timing indicator and the mounting plate. Remove the timing indicator and mounting plate from the timing chain cover.
  20.  
  21. Remove the timing case cover by removing the mounting bolts.
  22.  
  23. Position the timing chain cover on a clean work space with the outer face of the cover facing down. Arrange wooden blocks under the cover so that there is room under the oil seal so that it can be driven out of the cover. Use an oil seal driver tool, or a socket which is sized so that it sits on the oil seal, to gently drive the oil seal out of the cover.
  24.  

To install:
  1. Clean the gasket surfaces on the timing chain cover and engine block of all oil, grime and old gasket material.
  2.  
  3. Lightly coat the outer diameter of the oil seal with Loctite® Stud N' Bearing Mount (PN-4057987), or equivalent.
  4.  
  5. Set the timing chain cover on the work space with the outer face of the cover facing up. Position a new oil seal in the oil seal bore, then gently drive the oil seal into the cover with an oil seal installer too or aptly sized socket. Make certain that the oil seal does not become cocked in the bore and that it is seated fully in the bore. Lubricate the oil seal lip with clean engine oil.
  6.  
  7. Clean the oil seal-to-crankshaft portion of the crankshaft stub.
  8.  
  9. Fit new chain cover gaskets to the chain case. Trim the gaskets as required to assure correct fit at the top and bottom.
  10.  
  11. Coat the cover gaskets with Chrysler Sealant 3419115, or equivalent, and install the coated gaskets and chain cover onto the engine block. Make sure not to damage the oil seal. Tighten the mounting bolts until snug.
  12.  
  13. Install the cylinder head and tighten the cylinder head-to-timing chain cover bolts to 13 ft. lbs. (18 Nm).
  14.  
  15. Install the oil screen and the oil pan, as described earlier in this section.
  16.  
  17. Install the crankshaft pulley, as described earlier in this section. Tighten the pulley mounting bolt to 87 ft. lbs. (118 Nm).
  18.  
  19. Install the alternator and the distributor. For more information, refer to Engine Electrical .
  20.  
  21. Install the accessory drive belts, as described earlier in this section.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Install the cooling fan and radiator. For more information, refer to the procedures earlier in this section.
  26.  
  27. Fill the system with coolant, start the engine and check for coolant, oil and fuel leaks.
  28.  

OIL SEAL REPLACEMENT WITH TIMING CASE COVER INSTALLED
  1. Remove the crankshaft drive pulley, as described earlier in this section under vibration damper removal and installation procedures.
  2.  
  3. Pry the oil seal out of the cover, taking care not to nick or damage the sealing surfaces.
  4.  

To install:
  1. Install a new oil seal. Lightly coat the outside diameter with Loctite® Stud N' Bearing Mount (PN-4057987) or equivalent.
  2.  
  3. Install the crankshaft drive pulley. Tighten the bolt to 87 ft. lbs. (118 Nm).
  4.  

 
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