Removal & Installation
2.5L & 4.0L Engines
- Disconnect negative cable from battery.
- Remove the fan and shroud.
- Remove the serpentine drive belt.
- Remove the crankshaft vibration damper.
- Remove the timing case cover.
- Rotate crankshaft until the -0- timing mark is closest to and on the center line with camshaft sprocket timing mark.
- Remove the oil slinger from the crankshaft.
- Remove the camshaft sprocket bolt and washer.
- Remove the crankshaft sprocket, camshaft sprocket and timing chain as an assembly.
Installation of the timing chain with the timing marks on the crankshaft and camshaft sprockets properly aligned ensures correct valve timing. A worn or stretched timing chain will adversely affect valve timing. If the timing chain deflects more than 12.7 mm ( 1 / 2 inch) replace it.
- For 2.5L engines, turn the timing chain tensioner lever to the unlock (down) position. Pull the tensioner block toward the tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position.
- Apply Mopar® Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key. With the key in the keyway on the crankshaft, install the assembly on the crankshaft and camshaft.
- Install the camshaft sprocket bolt and washer. Tighten the bolt to 80 ft. lbs. (108 Nm) for 2.5L engines; 50 ft. lbs. (68 Nm) for 4.0L engines.
- For 2.5L engines, release the timing chain tensioner.
- To verify correct installation of the timing chain, rotate the crankshaft 2 revolutions. The camshaft and crankshaft sprocket timing mark should align.
- Install the crankshaft oil slinger.
- Replace the oil seal in the timing case cover.
- Install Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening to center the front cover
- Torque the front cover bolts as follows: Step 1: Cover-to-block 14 inch bolts to 60 inch lbs. (7 Nm); Step 2: Cover-to-block 516 inch bolts to 16 ft. lbs. (22 Nm); Step 3: Oil pan-to-cover 14 inch bolts to 85 inch lbs. (9.5 Nm); Step 4: Oil pan-to-cover 516 inch bolts to 11 ft. lbs. (15 Nm).
- With the key installed in the crankshaft keyway, install the vibration damper. Torque to 80 ft. lbs.
- Install the serpentine drive belt.
- Install the fan, hub assembly and shroud.
- Connect negative cable to battery.
Assemble the timing chain, crankshaft sprocket and camshaft sprocket with the timing marks aligned.
- Disconnect negative cable from battery.
- Drain cooling system.
- Remove right and left cylinder head covers.
- Remove radiator fan shroud.
- Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover and the camshaft sprocket -V6- marks are at the 12 o-clock position (#1 TDC exhaust stroke).
- Remove power steering pump.
- Remove access plug from left and right cylinder heads for access to chain guide fasteners .
- Remove the oil fill housing to gain access to the right side tensioner arm fastener.
- Remove crankshaft damper and timing chain cover.
Collapse and pin primary chain tensioner.
CAUTIONPlate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening.
- Remove secondary chain tensioners.
Remove camshaft position sensor .
CAUTIONCare should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition.
CAUTIONDo not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement.
- Remove left and right camshaft sprocket bolts.
- While holding the left camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral position.
- While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench, remove the right camshaft sprocket.
- Remove idler sprocket assembly bolt.
- Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains.
- Remove both pivoting tensioner arms and chain guides.
- Remove primary chain tensioner.
- Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner.
- While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin.
- Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 250 inch lbs. (28 Nm).
Install right side chain tensioner arm. Install Torx®bolt. Tighten Torx®bolt to 250 inch lbs. (28 Nm).
CAUTIONThe silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
- Install the left side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
- Install left side chain tensioner arm, and Torx®bolt. Tighten Torx®bolt to 250 inch lbs. (28 Nm).
- Install the right side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
- Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o-clock and 8 o-clock). Once the secondary timing chains are installed, position special tool 8429 to hold chains in place for installation.
- Align primary chain double plated links with the timing mark at 12 o-clock on the idler sprocket.
- Align the primary chain single plated link with the timing mark at 6 o-clock on the crankshaft sprocket.
Lubricate idler shaft and bushings with clean engine oil.
NOTEThe idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated.
Install all chains, crankshaft sprocket, and idler sprocket as an assembly . After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or equivalent. This will maintain tension on chains to aid in installation. Align the timing mark on the idler sprocket gear to the timing mark on the counterbalance shaft drive gear, then seat idler sprocket fully . Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 25 ft. lbs. (34 Nm).
NOTEIt will be necessary to slightly rotate camshafts for sprocket installation.
- Align left camshaft sprocket -L- dot to plated link on chain.
Align right camshaft sprocket -R- dot to plated link on chain.
CAUTIONRemove excess oil from the camshaft sprocket bolt. Failure to do so can result in over torque of bolt resulting in bolt failure.
- Remove Special Tool 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
Verify that all plated links are aligned with the marks on all sprockets and the -V6- marks on camshaft sprockets are at the 12 o-clock position.
CAUTIONEnsure the plate between the left secondary chain tensioner and block is correctly installed.
Install both secondary chain tensioners. Tighten bolts to 250 inch lbs. (28 Nm).
NOTELeft and right secondary chain tensioners are not common.
Remove all locking pins from tensioners.
CAUTIONAfter pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.
- Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left and right . camshaft sprocket bolts to 90 ft. lbs. (122 Nm).
- Rotate engine two full revolutions. Verify timing marks are at the follow locations: ² primary chain idler sprocket dot is at 12 o-clock ² primary chain crankshaft sprocket dot is at 6 o-clock ² secondary chain camshaft sprockets -V6- marks are at 12 o-clock ² counter balancer shaft drive gear dot is aligned to the idler sprocket gear dot.
- Lubricate all three chains with engine oil.
- After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within mm 0.004-0.010 inches (0.10-0.25). If not within specification, the idler gear must be replaced.
- Install timing chain cover and crankshaft damper.
Install cylinder head covers.
NOTEBefore installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
- Coat the large threaded access plug with Mopar® Thread Sealant with Teflon, then install into the right cylinder head and tighten to 60 ft. lbs. (81 Nm).
- Install the oil fill housing.
- Install access plug in left cylinder head.
- Install power steering pump.
- Fill cooling system.
- Connect negative cable to battery.