Durango, 2001-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



3.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Valve covers
     
    Radiator fan
     

  6.  
  7. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V6 marks on the camshaft sprockets are at 12 o-clock.

    Power steering pump
     
    Access plugs from the cylinder heads
     
    Oil fill housing
     
    Crankshaft damper

    Click image to see an enlarged view

    Fig. Camshaft sprocket timing marks-3.7L engine

    Camshaft sprocket timing marks-3.7L engine

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-3.7L engine

    Crankshaft timing marks-3.7L engine

    Click image to see an enlarged view

    Fig. Cylinder head access plugs-3.7L engine

    Cylinder head access plugs-3.7L engine
     

  8.  
  9. Compress the primary timing chain tensioner and install a lockpin.
  10.  
  11. Remove the secondary timing chain tensioners.
  12.  
  13. Hold the left camshaft with adjustable pliers and remove the sprocket and chain. Rotate the left camshaft 15 degrees clockwise to the neutral position.
  14.  
  15. Hold the right camshaft with adjustable pliers and remove the camshaft sprocket. Rotate the right camshaft 45 degrees counterclockwise to the neutral position.
  16.  
  17. Remove the primary timing chain and sprockets.
  18.  

To install:

Click image to see an enlarged view

Fig. Secondary timing chain tensioner preparation-3.7L engine

Secondary timing chain tensioner preparation-3.7L engine

  1. Use a small prytool to hold the ratchet pawl and compress the secondary timing chain tensioners in a vise and install locking pins.
    NOTE
    The black bolts fasten the guide to the engine block and the silver bolts fasten the guide to the cylinder head.

  2.  
  3. Install or connect the following:

    Secondary timing chain guides. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Secondary timing chains to the idler sprocket so that the double plated links on each chain are visible through the slots in the primary idler sprocket
     

  4.  
  5. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool as shown.

    Click image to see an enlarged view

    Fig. Installing the idler gear and timing chain-3.7L engine

    Installing the idler gear and timing chain-3.7L engine

    Click image to see an enlarged view

    Fig. Counterbalance shaft timing marks-3.7L engine

    Counterbalance shaft timing marks-3.7L engine

    Click image to see an enlarged view

    Fig. Tightening the left side camshaft sprocket-3.7L engine

    Tightening the left side camshaft sprocket-3.7L engine

    Click image to see an enlarged view

    Fig. Tightening the right side camshaft sprocket-3.7L engine

    Tightening the right side camshaft sprocket-3.7L engine

    Click image to see an enlarged view

    Fig. Use the Timing Chain Locking tool to lock the timing chains on the idler gear-3.7L engine

    Use the Timing Chain Locking tool to lock the timing chains on the idler gear-3.7L engine

    Click image to see an enlarged view

    Fig. Timing chain system and alignment marks-3.7L engine

    Timing chain system and alignment marks-3.7L engine
  6.  
  7. Align the primary chain double plated links with the idler sprocket timing mark and the single plated link with the crankshaft sprocket timing mark.
  8.  
  9. Install the primary chain and sprockets. Tighten the idler sprocket bolt to 25 ft. lbs. (34 Nm).
  10.  
  11. Align the secondary chain single plated links with the timing marks on the secondary sprockets. Align the dot at the L mark on the left sprocket with the plated link on the left chain and the dot at the R mark on the right sprocket with the plated link on the right chain.
  12.  
  13. Rotate the camshafts back from the neutral position and install the camshaft sprockets.
  14.  
  15. Remove the secondary chain locking tool.
  16.  
  17. Remove the primary and secondary timing chain tensioner locking pins.
  18.  
  19. Hold the camshaft sprockets with a spanner wrench and tighten the retaining bolts to 90 ft. lbs. (122 Nm).

    Click image to see an enlarged view

    Fig. Timing cover bolt torque sequence-3.7L engine

    Timing cover bolt torque sequence-3.7L engine
  20.  
  21. Install or connect the following:

    Front cover. Tighten the bolts, in sequence, to 40 ft. lbs. (54 Nm).
     
    Front crankshaft seal
     
    Cylinder head access plugs
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt tensioner. Tighten the bolt to 40 ft. lbs. (54 Nm).
     
    Oil fill housing
     
    Crankshaft damper. Tighten the bolt to 130 ft. lbs. (175 Nm).
     
    Power steering pump
     
    Lower radiator hose
     
    Heater hoses
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Camshaft Position (CMP) sensor
     
    Valve covers
     
    Negative battery cable
     

  22.  
  23. Fill and bleed the cooling system.
  24.  
  25. Start the engine, check for leaks and repair if necessary.
  26.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Valve covers
     
    Camshaft Position (CMP) sensor
     
    Engine cooling fan and shroud
     
    Accessory drive belt
     
    Heater hoses
     
    Lower radiator hose
     
    Power steering pump
     

  6.  
  7. Rotate the crankshaft so that the crankshaft timing mark aligns with the Top Dead Center (TDC) mark on the front cover, and the V8 marks on the camshaft sprockets are at 12 o-clock.

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-4.7L engine

    Crankshaft timing marks-4.7L engine

    Click image to see an enlarged view

    Fig. Camshaft positioning-4.7L engine

    Camshaft positioning-4.7L engine
  8.  
  9. Remove or disconnect the following:

    Crankshaft damper
     
    Oil fill housing
     
    Accessory drive belt tensioner
     
    Alternator
     
    A/C compressor
     
    Front cover
     
    Front crankshaft seal
     
    Cylinder head access plugs
     
    Secondary timing chain guides

    Click image to see an enlarged view

    Fig. Cylinder head access plug locations-4.7L engine

    Cylinder head access plug locations-4.7L engine

    Click image to see an enlarged view

    Fig. Compress and lock the primary chain tensioner-4.7L engine

    Compress and lock the primary chain tensioner-4.7L engine
     

  10.  
  11. Compress the primary timing chain tensioner and install a lockpin.
  12.  
  13. Remove the secondary timing chain tensioners.
  14.  
  15. Hold the left camshaft with adjustable pliers and remove the sprocket and chain. Rotate the left camshaft 15 degrees clockwise to the neutral position.
  16.  
  17. Hold the right camshaft with adjustable pliers and remove the camshaft sprocket. Rotate the right camshaft 45 degrees counterclockwise to the neutral position.
  18.  
  19. Remove the primary timing chain and sprockets.
  20.  

To install:

Click image to see an enlarged view

Fig. Secondary timing chain tensioner preparation-4.7L engine

Secondary timing chain tensioner preparation-4.7L engine

  1. Use a small prytool to hold the ratchet pawl and compress the secondary timing chain tensioners in a vise and install locking pins.
    NOTE
    The black bolts fasten the guide to the engine block and the silver bolts fasten the guide to the cylinder head.

  2.  
  3. Install or connect the following:

    Secondary timing chain guides. Tighten the bolts to 21 ft. lbs. (28 Nm).
     
    Secondary timing chains to the idler sprocket so that the double plated links on each chain are visible through the slots in the primary idler sprocket
     

  4.  
  5. Lock the secondary timing chains to the idler sprocket with Timing Chain Locking tool 8515 as shown.

    Click image to see an enlarged view

    Fig. Use the Timing Chain Locking tool to lock the timing chains on the idler gear-4.7L engine

    Use the Timing Chain Locking tool to lock the timing chains on the idler gear-4.7L engine

    Click image to see an enlarged view

    Fig. Timing chain system and alignment marks-4.7L engine

    Timing chain system and alignment marks-4.7L engine
  6.  
  7. Align the primary chain double plated links with the idler sprocket timing mark and the single plated link with the crankshaft sprocket timing mark.
  8.  
  9. Install the primary chain and sprockets. Tighten the idler sprocket bolt to 25 ft. lbs. (34 Nm).
  10.  
  11. Align the secondary chain single plated links with the timing marks on the secondary sprockets. Align the dot at the L mark on the left sprocket with the plated link on the left chain and the dot at the R mark on the right sprocket with the plated link on the right chain.
  12.  
  13. Rotate the camshafts back from the neutral position and install the camshaft sprockets.
  14.  
  15. Remove the secondary chain locking tool.
  16.  
  17. Remove the primary and secondary timing chain tensioner locking pins.
  18.  
  19. Hold the camshaft sprockets with a spanner wrench and tighten the retaining bolts to 90 ft. lbs. (122 Nm).

    Click image to see an enlarged view

    Fig. Timing chain cover bolt torque sequence-4.7L engine

    Timing chain cover bolt torque sequence-4.7L engine
  20.  
  21. Install or connect the following:

    Front cover. Tighten the bolts, in sequence, to 40 ft. lbs. (54 Nm).
     
    Front crankshaft seal
     
    Cylinder head access plugs
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt tensioner. Tighten the bolt to 40 ft. lbs. (54 Nm).
     
    Oil fill housing
     
    Crankshaft damper. Tighten the bolt to 130 ft. lbs. (175 Nm).
     
    Power steering pump
     
    Lower radiator hose
     
    Heater hoses
     
    Accessory drive belt
     
    Engine cooling fan and shroud
     
    Camshaft Position (CMP) sensor
     
    Valve covers
     
    Negative battery cable
     

  22.  
  23. Fill the cooling system.
  24.  
  25. Start the engine and check for leaks.
  26.  

5.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt
     
    Radiator fan
     
    Coolant and washer bottles
     
    Fan shroud
     
    A/C compressor
     
    Alternator
     
    Radiator and heater hoses
     
    Tensioner and idler pulleys
     
    Crankshaft damper
     
    Power steering pump
     
    Oil pan and pickup tube
     
    Timing cover
     
    Re-install the damper
     

  6.  
  7. Rotate the crankshaft so that the camshaft sprocket and crankshaft sprocket timing marks are aligned.
    NOTE
    The camshaft pin and slot in the cam sprocket must be a 12 o-clock, the crankshaft keyway must be at 2 o-clock, and the dots or paint on the crank sprocket must be at 6 o-clock.

  8.  
  9. Pin back the tensioner shoe.
  10.  
  11. Remove the timing chain and sprockets.
  12.  

To install:

  1. With the timing marks aligned, wrap the chain around the sprockets. The chain must be installed with the single plated link aligned with the dot or paint on the cam sprocket. The dot or paint on the crank sprocket should be aligned between the 2 plated links.

    Click image to see an enlarged view

    Fig. Timing mark alignment-5.7L engine

    Timing mark alignment-5.7L engine
  2.  
  3. Install the assembly and torque the cam sprocket bolt to 90 ft. lbs. (122 Nm).
  4.  
  5. Unpin the tensioner and verify the alignment.
  6.  
  7. Install or connect the following:

    Timing cover. Torque all fasteners to 21 ft. lbs. (28 Nm). Torque the large lifting lug to 40 ft. lbs. (55 Nm)
     
    Oil pan and pickup tube
     
    Power steering pump
     
    Crankshaft damper
     
    Tensioner and idler pulleys
     
    Radiator and heater hoses
     
    Alternator
     
    A/C compressor
     
    Fan shroud
     
    Coolant and washer bottles
     
    Radiator fan
     
    Drive belt
     
    Negative battery cable
     

  8.  

5.9L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Cooling fan and shroud
     
    Water pump
     
    Power steering pump
     
    Crankshaft damper
     
    Front crankshaft seal
     
    Front cover
     

  6.  
  7. Rotate the crankshaft so that the camshaft sprocket and crankshaft sprocket timing marks are aligned.
  8.  
  9. Remove the timing chain and sprockets.
  10.  

To install:

  1. Install the timing chain and sprockets with the timing marks aligned. Tighten the camshaft sprocket bolt to 50 ft. lbs. (68 Nm).
  2.  
  3. Install or connect the following:

    Front cover. Tighten the cover bolts to 30 ft. lbs. (41 Nm) and the oil pan bolts to 18 ft. lbs. (24 Nm).
     
    Front crankshaft seal
     
    Crankshaft damper. Tighten the bolt to 135 ft. lbs. (183 Nm).
     
    Power steering pump
     
    Water pump
     
    Cooling fan and shroud
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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