Chrysler Full-Size Trucks 1989-1996 Repair Guide

Timing Chain Cover

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The 2.5L engine uses a timing belt. For information, please refer to the appropriate section in this guide. All other gasoline engines do have a timing chain, and are covered here.

REMOVAL & INSTALLATION



3.9L Engine

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  



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Fig. Fig. 1: Unbolt and remove the crankshaft pulley

  1. If necessary, remove the radiator, fan and all related parts.
  2.  
  3. Remove the water pump.
  4.  



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Fig. Fig. 2: Use a long-handled breaker bar to provide enough leverage to remove the crankshaft damper bolt

  1. Remove the crankshaft pulley.
  2.  



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Fig. Fig. 3: Use a suitable puller tool to remove the crankshaft damper

  1. Remove the vibration damper using the proper puller.
  2.  
  3. Disconnect the fuel lines from the fuel pump, if equipped.
  4.  
  5. Remove the two front bolts from the oil pan.
  6.  



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Fig. Fig. 4: When fully accessible, unbolt the timing chain cover

  1. Unbolt the chain cover from the block and remove, using caution to avoid damaging the oil pan gasket.
  2.  



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Fig. Fig. 5: Separate the timing chain cover to access the chain

To install:
  1. Clean and dry the mating surfaces of the cover and block. Apply a thin bead of sealer to the oil pan gasket.
  2.  
  3. Install a new cover gasket and install the cover. Tighten the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install the water pump with a new gasket.
  6.  
  7. Install the vibration damper with tool C-3638, or equivalent. Install the bolt and washer and tighten to specification. Apply a small amount of sealer to the bolts and install the crankshaft pulley.
  8.  
  9. Install the fuel pump using a new gasket, if equipped and connect the fuel lines. Install the two oil pan bolts.
  10.  
  11. Install the radiator, fan and all related parts.
  12.  
  13. Fill the cooling system.
  14.  
  15. Connect the negative battery cable and check for leaks.
  16.  

5.2L and 5.9L Engines

See Figures 6, 7 and 8

  1. Remove the water pump.
  2.  
  3. Remove the power steering pump.
  4.  
  5. Remove the crankshaft pulley.
  6.  
  7. Remove the vibration damper with a puller. Remove the fuel lines and fuel pump, then loosen the oil pan bolts and remove the front bolt on each side.
  8.  



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Fig. Fig. 6: Remove the vibration damper with a puller

  1. Remove the timing chain cover and the crankshaft oil slinger.
  2.  

To install:
  1. Clean all gasket surfaces thoroughly.
  2.  
  3. Install a new seal in the case.
  4.  
  5. Install the timing case cover with a new gasket. A 1 / 8 in. (3mm) bead of RTV sealer is recommended on the oil pan gasket. Tighten the cover bolts of 30 ft. lbs. (41 Nm). Retighten the engine oil pan to 17 ft. lbs. (23 Nm). Always use a centering tool to ensure that the seal will not be damaged and that it is properly aligned.
  6.  
  7. Lubricate the seal lip with lithium white grease and slide the damper back into position. Using tool C-3688, or equivalent, press the damper onto the shaft. Tighten the bolt to 135 ft. lbs. (183 Nm).
  8.  



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Fig. Fig. 7: Use a prytool to remove the front seal from the timing chain cover



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Fig. Fig. 8: Use a centering tool to install the front cover seal

  1. Install the fuel pump and lines.
  2.  
  3. Install the water pump.
  4.  
  5. Install the power steering pump.
  6.  
  7. Replace the radiator and hoses.
  8.  
  9. Tighten the drive belt(s).
  10.  

8.0L Engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Remove the fan shroud and fan.
  8.  
  9. Unbolt the A/C compressor and set it on top of the engine.
  10.  
  11. Remove the alternator, air pump and bracket.
  12.  
  13. Remove the water pump.
  14.  
  15. Remove the crankshaft pulley/damper with a 3-prong puller.
  16.  
  17. Loosen the oil pan bolts and remove the front bolts that mount the pan to the timing chain cover.
  18.  
  19. Remove the timing chain cover and the gasket using extreme caution to avoid damaging the oil pan gasket.
  20.  
  21. Inspect the cover surface. Remove any burrs or high spots.
  22.  

To install:
  1. Clean all gasket surfaces thoroughly.
  2.  
  3. Install a new seal in the case.
  4.  
  5. Install the timing case cover with a new gasket. A 1/8 in. (3mm) bead of RTV sealer is recommended on the oil pan gasket. Tighten the cover bolts to 35 ft. lbs. (47 Nm). Retighten the engine oil pan to 215 inch lbs. (24 Nm). Always use a centering tool to ensure that the seal will not be damaged and that it is properly aligned.
  6.  
  7. Lubricate the seal lip with lithium white grease and slide the damper back into position. Using tool C-3688, or equivalent, press the pulley/vibration damper onto the shaft. Tighten the bolt to 135 ft. lbs. (183 Nm).
  8.  
  9. Prime the oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front timing cover. When oil is running out, quickly install the filter (that has also been filled with oil).
  10.  
  11. Install the alternator, air pump and bracket.
  12.  
  13. Install the A/C compressor.
  14.  
  15. Install the cooling fan. Tighten the bolts to 17 ft. lbs. (23 Nm).
  16.  
  17. Install the fan shroud. Tighten the bolts to 95 inch lbs. (11 Nm).
  18.  
  19. Install the serpentine belt.
  20.  
  21. Fill the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Road test the vehicle to check for leaks.
  26.  

 
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