Chrysler Full-Size Vans 1967-1988 Repair Guide

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REMOVAL & INSTALLATION



See Figures 1 through 10



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Fig. Fig. 1: Although it is not necessary, the power steering pump can be unbolted (arrows) ...



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Fig. Fig. 2: ... and positioned out of the way to allow better access to the front cover



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Fig. Fig. 3: Remove all of the accessory belts. If equipped, remove the three pulley attaching bolts ...



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Fig. Fig. 4: ... and remove the pulley



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Fig. Fig. 5: Attach a puller onto the crankshaft dampener. Use a pry bar to prevent the engine from turning



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Fig. Fig. 6: Once loosened, remove the dampener from the crankshaft



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Fig. Fig. 7: Remove the oil pan-to-front cover attaching bolts ...



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Fig. Fig. 8: ... and the front cover-to-engine block retaining bolts



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Fig. Fig. 9: Gently pry the cover loose ...



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Fig. Fig. 10: ... and pull it free of the engine

Inline 6-Cylinder Engines
  1. Drain the cooling system and disconnect the battery.
  2.  


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.

  1. Remove the radiator and fan.
  2.  
  3. With a puller, remove the vibration damper.
  4.  
  5. Loosen the oil pan bolts to allow clearance, and remove the timing case cover and gasket.
  6.  

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 and torque the bolts to 17 ft. lbs. Retighten the engine oil pan to 17 ft. lbs. Always use a centering tool to ensure that the seal will not be damaged and that it is properly aligned.
  6.  
  7. Press the vibration damper back on.
  8.  
  9. Replace the radiator and hoses.
  10.  
  11. Refill the cooling system.
  12.  

V6 and V8 Engines

See Figures 11 through 17



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Fig. Fig. 11: To remove the V8 engine timing cover, remove the water pump, then unbolt the crankshaft pulley



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Fig. Fig. 12: To ease assembly, align the TDC mark on the pulley to the 0°mark on the cover



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Fig. Fig. 13: Loosen and remove the crankshaft balancer retaining bolt



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Fig. Fig. 14: Use a threaded puller to remove the balancer from the crankshaft



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Fig. Fig. 15: Remove any remaining attaching bolts and remove the cover



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Fig. Fig. 16: Position a new gasket onto the timing cover and coat with a bead of sealer



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Fig. Fig. 17: Also, use a bead of sealer on the oil pan gasket mating surfaces

  1. Disconnect the battery and drain the cooling system. Remove the radiator.
  2.  


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.

  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. On 318 and 360 engines, remove the fuel lines and fuel pump, then loosen the oil pan bolts and remove the front bolt on each side.
  8.  
  9. Remove the timing gear cover and the crankshaft oil slinger.
  10.  

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 " bead of RTV sealer is recommended on the oil pan gasket. Torque the cover bolts to 30 ft. lbs. Retighten the engine oil pan to 17 ft. lbs. 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, press the damper onto the shaft. Torque the bolt to 135 ft. lbs.
  8.  
  9. Install the fuel pump and lines.
  10.  
  11. Install the water pump.
  12.  
  13. Install the power steering pump.
  14.  
  15. Replace the radiator and hoses.
  16.  
  17. Tighten all drive belts.
  18.  

Diesel Engine
  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


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.

  1. Remove the upper and lower hoses.
  2.  
  3. Disconnect the overflow tank.
  4.  
  5. Remove the automatic transmission oil cooler lines and bracket.
  6.  
  7. Loosen the radiator mount bolts.
  8.  
  9. Remove the fan.
  10.  
  11. Remove the rubber shield from between the radiator and grille.
  12.  
  13. Remove the radiator and fan shroud.
  14.  
  15. Remove all drive belts.
  16.  
  17. Remove the crankshaft pulley nut.
  18.  
  19. Turn the crankshaft until the keyway is at the 12 o'clock position.
  20.  
  21. Remove the crankshaft pulley and damper assembly with tool MH-061101.
  22.  
  23. Remove the timing gear case and gasket.
  24.  
  25. Remove the front oil seal from the case.
  26.  

To install:
  1. Coat a new timing case gasket with sealer and position it over the dowels on the block.
  2.  
  3. Install the timing gear case. Torque the bolts to 84 in. lb. (7 ft. lbs.).
  4.  
  5. Install the crankshaft pulley and damper assembly. Be careful to avoid damage to the seal.
  6.  
  7. Install the the crankshaft pulley cone and nut. Torque the nut to 290 ft. lbs.
  8.  
  9. Install all drive belts.
  10.  
  11. Install the radiator and fan shroud. Tighten the lower radiator mounting nuts finger-tight.
  12.  
  13. Install the rubber shield between the radiator and grille.
  14.  
  15. Install the fan.
  16.  
  17. Align the radiator and tighten the radiator mount bolts.
  18.  
  19. Install the automatic transmission oil cooler lines and bracket.
  20.  
  21. Connect the overflow tank.
  22.  
  23. Install the upper and lower hoses.
  24.  
  25. Fill the cooling system.
  26.  
  27. Connect the battery ground cable.
  28.  

 
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