Sprinter 2005-2007

Timing Chain Cover & Seal

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Removal & Installation



2.7L Engine
  1. Disconnect negative battery cable.
    NOTE
    Rotate engine on crankshaft. DO NOT crank the engine at the bolt of the camshaft sprocket.


    NOTE
    DO NOT crank engine back.

  2.  
  3. Position piston of cylinder 1 to ignition TDC. Markings on the camshaft bearing cap must be aligned.
  4.  
  5. Drain coolant.
  6.  
  7. Install retaining lock for crankshaft/starter ring gear.
  8.  
  9. Drain engine oil.
  10.  
  11. Remove the oil filter to allow the oil to flow off into the oil pan.
  12.  
  13. Remove the radiator assembly.
  14.  
  15. Remove engine cover.
  16.  
  17. Remove front cover at cylinder head.
  18.  
  19. Remove accessory drive belt.
  20.  
  21. Remove the high pressure fuel pump.
  22.  
  23. Remove water pump.
  24.  
  25. Remove accessory drive belt pulley and vibration damper.
  26.  
  27. Remove the power steering pump.
    NOTE
    DO NOT open the air conditioning system.

  28.  
  29. Unplug AC compressor electrical connector and unbolt AC compressor. Relocate in lower engine compartment with out opening the system.
  30.  
  31. Remove the generator with wiring attached and relocate somewhere in the engine compartment.
  32.  
  33. Install engine support fixture.
  34.  
  35. Remove the oil pan.
  36.  
  37. Detach the coolant hose to oil-water heat exchanger at crankcase.
  38.  
  39. Remove the cylinder head to timing cover bolts.
  40.  
  41. Remove the timing cover bolts and cover.
  42.  
  43. Remove remaining ancillary components attached to the timing case cover.
    NOTE
    Inspect condition of hoses and clamps, replace as necessary.

  44.  
  45. Remove timing chain tensioner.
  46.  
  47. Remove timing case cover.
  48.  

To install:


CAUTION
Care must be taken to closely inspect the gasket area around the time case cover to cylinder head gasket coolant port. If damage is found, replace the cylinder head gasket. Failure to do so may result in engine damage.


NOTE
Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during assembly.

  1. Inspect cylinder head gasket and oil pan gasket. If damaged, replace.
  2.  
  3. Replace the front crankshaft seal.
  4.  
  5. Install ancillary components to timing case cover.
  6.  
  7. Apply sealant to the marked surfaces with a bead thickness of 1.5 ± 0.5 mm.
    NOTE
    Install timing cover within 10 minutes after applying sealant. Do not spread sealant bead.


    NOTE
    Do not seal pressurized oil galleries to the crankcase. Sealant applied at these points is entrained by the oil flow and blocks the oil supply passages.

  8.  
  9. Position and install timing case cover. Tighten bolts to 177 inch lbs. (20 Nm).
  10.  
  11. Install the M8 bolts of cylinder head on timing case cover. Tighten bolts to 177 inch lbs. (20 Nm).
  12.  
  13. Install timing chain tensioner with new seal.
  14.  
  15. Position and install the oil pan. Tighten M6 bolts to 80 inch lbs. (9 Nm) and M8 bolts to 177 inch lbs. (20 N·m).
  16.  
  17. Install belt /pulley vibration damper. Tighten M8.8 bolt in two stages, 147 ft. lbs. (200N·m) then 90°, M10.9 bolt 240 ft. lbs. (325N·m) then 90°.
  18.  
  19. Remove the engine support fixture.
  20.  
  21. Install generator.
  22.  
  23. Install the air conditioning compressor.
  24.  
  25. Install the power steering pump.
  26.  
  27. Install water pump.
  28.  
  29. Connect coolant hose to oil-water heat exchanger.
  30.  
  31. Install high pressure fuel pump.
  32.  
  33. Apply sealant to lower portion of, and install, front cover to cylinder block. Tighten bolts to 177 inch lbs. (20N·m).
  34.  
  35. Remove retaining lock for crankshaft/starter ring gear.
  36.  
  37. Tighten the oil drain plug to 265 inch lbs. (30 Nm).
  38.  
  39. Install a new oil filter. tighten screw cap for filter to 221 inch lbs. (25 Nm).
  40.  
  41. Install the accessory drive belt.
  42.  
  43. Install the radiator assembly.
  44.  
  45. Install air intake hose.
  46.  
  47. Fill coolant to the proper level, with the proper coolant.
  48.  
  49. Fill the crankcase with the correct oil, to the proper level. Refer to owner-s manual for specifications.
  50.  
  51. Connect the negative battery cable.
    CAUTION
    DO NOT pressure test cooling system until the engine reaches operating temperature.

  52.  
  53. Start engine and inspect for leaks. Care must be taken to observe the fuel system warning.
  54.  

3.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the power steering fluid.
  8.  
  9. Remove the engine appearance cover.
  10.  
  11. Remove the front engine cover bracket.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the power steering hose between the pump and cooling fan.
  16.  
  17. Remove the power steering hose between the cooling fan and suspension.
  18.  
  19. Remove the lower cooling fan module retaining bolts.
  20.  
  21. Disconnect the cooling fan wiring harness connector.
  22.  
  23. Remove the power steering line between the retainer and cooling fan module.
  24.  
  25. Remove the front splash shield.
  26.  
  27. Remove the front oil pan to timing cover bolts.
  28.  
  29. Lower the vehicle.
  30.  
  31. Remove the hoses at the power steering reservoir.
  32.  
  33. Remove the cooling fan module upper bolts and remove the fan assembly.
  34.  
  35. Remove the charge air outlet tube.
  36.  
  37. Remove the accessory drive belt.
  38.  
  39. Disconnect the charge air inlet hose at the EGR air control valve.
  40.  
  41. Remove the glow plug module.
  42.  
  43. Remove the EGR air control valve.
  44.  
  45. Remove both accessory drive belt idler pulleys.
  46.  
  47. Remove the accessory drive belt tensioner.
  48.  
  49. Rotate the engine to Top Dead Center (TDC) by the crankshaft bolt.
  50.  
  51. Raise and safely support the vehicle.
  52.  
  53. Remove the starter blank.
  54.  
  55. Install Special Tool 9102 Crankshaft Lock.
  56.  
  57. Lower the vehicle.
  58.  
  59. Remove the vibration damper and pulley.
  60.  
  61. Remove the front timing cover seal.
  62.  
  63. Remove the front timing cover bolts and cover.
  64.  
  65. Pry the front oil seal from the front cover, if necessary.
  66.  

To install:

  1. Install the front crankshaft seal in the timing cover.
  2.  
  3. Install the timing cover and tighten bolts to 80 inch lbs. (9 Nm).
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the front oil pan bolts and tighten the bolts to 88 inch lbs. (10 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the vibration damper and pulley. Tighten the bolt to 154 ft. lbs. (210 Nm) plus 180°.
  12.  
  13. Install the accessory drive belt tensioner. Tighten bolt to 43 ft. lbs. (58 Nm).
  14.  
  15. Install the idler pulleys and tighten the bolts to 20 ft. lbs. (28 Nm).
  16.  
  17. Install the accessory drive belt.
  18.  
  19. Install the EGR air control valve assembly.
  20.  
  21. Install the glow plug module.
  22.  
  23. Install the charge air outlet tube.
  24.  
  25. Install the cooling fan module. Tighten upper bolts to 10 ft. lbs. (14 Nm).
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove Special Tool 9102 Crankshaft Lock.
  30.  
  31. Install the starter blank.
  32.  
  33. Install the lower cooling fan module bolts and tighten the lower bolts to 10 ft. lbs. (14 Nm).
  34.  
  35. Install the power steering line between the retainer and cooling fan module.
  36.  
  37. Connect the cooling fan wiring harness connector.
  38.  
  39. Install the power steering hose between the cooling fan and suspension.
  40.  
  41. Install the power steering hose between the pump and cooling fan.
  42.  
  43. Install the front skid plate.
  44.  
  45. Lower the vehicle.
  46.  
  47. Install the hoses at the power steering reservoir.
  48.  
  49. Refill the power steering reservoir to the correct level.
  50.  
  51. Install the front engine cover bracket.
  52.  
  53. Install the engine cover.
  54.  
  55. Refill the cooling system to the correct level.
  56.  
  57. Refill the engine with oil to the correct level.
  58.  
  59. Connect the negative battery cable.
  60.  
  61. Purge the air from the power steering system before starting by raising the vehicle and rotating the steering wheel back and forth 20 times.
  62.  
  63. Start the engine and follow the bleed procedure with the scan tool.
  64.  
  65. Turn engine off and inspect for leaks.
  66.  

 
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