REMOVAL & INSTALLATION
- Drain the cooling system and crankcase.
- Disconnect the upper radiator hose from the intake manifold and the lower hose from the water pump. On cars with automatic transmissions, disconnect the cooler lines from the radiator.
- Remove the radiator, fan and pulley, and engine drive belts. On models with air conditioning, remove the condenser retaining bolts and position the condenser forward. Do not disconnect the refrigerant lines.
- Remove the cylinder front cover retaining bolts and front oil pan bolts and gently pry the cover away from the block.
- Remove the crankshaft pulley bolt and use a puller to remove the vibration damper.
- With a socket wrench of the proper size on the crankshaft pulley bolt, gently rotate the crankshaft in a clockwise direction until all slack is removed from the left side of the timing chain. Scribe a mark on the engine block parallel to the present position on the left side of the chain. Next, turn the crankshaft in a counterclockwise direction to remove all the slack from the right side of the chain. Force the left side of the chain outward with the fingers and measure the distance between the reference point and the present position of the chain. If the distance exceeds 1 / 2 inch, replace the chain and sprockets.
- Crank the engine until the timing marks are aligned as shown in the illustration. Remove the bolt, slide the sprocket and chain forward and remove it as an assembly.
- Position the sprockets and chain on the engine, making sure that the timing marks are aligned, dot to dot.
- Reinstall the front cover, applying oil resistant sealer to the new gasket.
Trim away the exposed portion of the old oil pan gasket flush with front of the engine block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it.
- Install the fan, pulley and belts. Adjust the belt tension.
- Install the radiator, connect the radiator hoses and transmission cooling lines. If equipped with air conditioning, install the condenser.
- Fill the crankcase and cooling system. Start the engine and check for leaks.
- Drain the cooling system, remove air cleaner and disconnect the battery.
- Disconnect automatic transmission oil cooler lines (if equipped), radiator hoses and remove the radiator.
- Disconnect heater hose at the water pump. Slide the water pump bypass hose clamp toward the pump.
- Loosen the alternator mounting bolts at the alternator. Remove the alternator support bolt at the water pump. Remove the Thermactor pump on all engines so equipped. If equipped with power steering or air conditioning, unbolt the component, remove the belt, and lay the pump aside with the lines attached.
- Remove the fan, spacer, pulley, and drive belt.
- Drain the crankcase.
- Remove the pulley from the crankshaft pulley adapter. Remove the capscrew and washer from the front end of the crankshaft. Remove the crankshaft pulley adapter with a puller.
- Disconnect the fuel pump outlet line at the pump. Remove the fuel pump retaining bolts and lay the pump to the side. Remove the engine oil dipstick.
- Remove the front cover attaching bolts.
- Remove the crankshaft oil slinger if so equipped.
- Check timing chain deflection, using the procedure outlined in Step 6 of the 200 cid (3.3L) Engine cover and chain removal procedure.
- Turn the engine until the sprocket timing marks are aligned as shown in the valve timing illustration.
- Remove the crankshaft sprocket capscrew, washers, and fuel pump eccentric. Slide both sprockets and chain forward and off as an assembly.
- Position the sprockets and chain on the camshaft and crankshaft with both timing marks dot to dot on the centerline. Install the fuel pump eccentric, washers and sprocket attaching bolt. Tighten the sprocket attaching bolt to 40-45 ft. lbs.
- Install the crankshaft front oil slinger.
- Clean the front cover and mating surfaces of old gasket material. Install a new oil seal in the cover. Use a seal driver tool or equivalent.
- Coat the new cover gasket with sealer and position it on the block.
Trim away the exposed portion of the oil pan gasket flush with the cylinder block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it.
- Install the front cover, using a crankshaft-to-cover alignment tool. Coat the threads of the attaching bolts with sealer. Tighten the attaching bolts to 12-15 ft. lbs.
- Install the fuel pump and connect the fuel pump outlet tube.
- Install the crankshaft pulley adapter and tighten the attaching bolt. Install the crankshaft pulley.
- Install the water pump pulley, drive belt, spacer and fan.
- Install the alternator support bolt at the water pump. Tighten the alternator mounting bolts. Adjust the drive belt tension. Install Thermactor pump, if so equipped.
- Install the radiator and connect all coolant and heater hoses. Connect the battery cables.
- Refill the cooling system and the crankcase. Install the dipstick.
- Start the engine and operate it at fast idle.
- Check for leaks, install the air cleaner. Adjust the ignition timing and make all final adjustments.
COVER OIL SEAL REPLACEMENT
Except 140 cid (2.3L) Engine
It is recommended to replace the cover seal any time the front cover is removed.
- With the cover removed from the car, drive the old seal from the rear of the cover with a pinpunch. Clean out the recess in the cover.
- Coat the new seal with grease and drive it into the cover until it is fully seated. Check the seal after installation to ensure the spring is properly positioned in the seal.