Sprinter 2005-2007

Timing Chain & Sprockets

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Removal & Installation



2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Turn the engine by the crankshaft and position cylinder No. 1 at Top Dead Center (TDC).
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the alternator wiring harness duct at the crankcase and set aside.
  12.  
  13. Remove the inspection cover.
  14.  
  15. Remove the bolts.
  16.  
  17. Insert the Special Tool 8932 Crankshaft Lock into the starter ring gear and install the retaining bolts. Tighten the lock bolts to 80 inch lbs. (9 Nm)
  18.  
  19. Remove the oil filter.
  20.  
  21. Remove the radiator. For additional information, refer to the following section, -Radiator, Removal & Installation.-
  22.  
  23. Remove the engine appearance cover.
  24.  
  25. Remove the front cover at cylinder head. For additional information, refer to the following section, -Cylinder Head, Removal & Installation.-
  26.  
  27. Remove the accessory drive belt.
  28.  
  29. Remove the high pressure fuel pump.
  30.  
  31. Remove the water pump.
  32.  
  33. Remove the accessory drive belt pulley and vibration damper.
  34.  
  35. Remove the power steering pump.
  36.  
  37. Unplug the A/C compressor electrical connector and unbolt the A/C compressor. Relocate it to the lower engine compartment.
    NOTE
    Do not disconnect the A/C lines.

  38.  
  39. Remove the alternator with the wiring attached and relocate somewhere in the engine compartment.
  40.  
  41. Install a suitable engine support fixture.
  42.  
  43. Remove the oil pan.
  44.  
  45. Detach the coolant hose to oil-water heat exchanger at crankcase.
  46.  
  47. Remove the cylinder head to timing cover bolts.
  48.  
  49. Remove the timing cover bolts and cover.
  50.  
  51. Remove the remaining ancillary components attached to the timing case cover.
  52.  
  53. Remove the timing chain tensioner.
  54.  
  55. Remove the timing chain front cover.
  56.  
  57. Pry the front oil seal from the timing chain cover, if necessary.
  58.  
  59. Install Special Tool 9525, using two of the cylinder head mounting bolts.

    Click image to see an enlarged view

    Fig. Install Special Tool 9525, using two of the cylinder head mounting bolts-2.7L Engine

  60.  
  61. Assemble Special Tool 9312-1 using 9312- 3 and 9312-4. Install Insert 9312-13 and retain with the screw provided.
    CAUTION
    Care must be taken not to drop the timing chain plates into the engine once the timing chain is separated.


    NOTE
    When installing Special Tool 9312-1 onto timing chain link, be sure to back off the smaller nut of the thrust pin 9312-3 until the pin is recessed inside of the spindle, 9312-4. Screw the thrust spindle 9312-4 in until it is seated and aligned properly over the rivet of the timing chain.


    NOTE
    When fitting the thrust spindle, ensure that the thrust pin is positioned at the left timing chain pin of a chain link.



    Click image to see an enlarged view

    Fig. Assemble Special Tool 9312-1 (1) using 9312- 3 (3) and 9312-4 (4) and install Insert 9312-13 (2) and secure with the provided screw-2.7L Engine

  62.  
  63. Install Special Tool 9312 onto timing chain link.
    NOTE
    Cover the timing chain area. Care must be taken not to drop any repair debris or pieces into the engine when separating the timing chain links.

  64.  
  65. Carefully turn 9312-3 Thrust Pin of Special Tool 9312-1 clockwise while holding the handle until the rivet is pressed out and the chain is separated. Discard the loose link and plates.
    NOTE
    One whole timing chain link must be removed.


    NOTE
    Care must be taken not to drop any repair debris or pieces into the engine when separating the timing chain links.

  66.  

To install:

  1. Connect a new timing chain with the oil holes facing up, and old timing chain with the assembly link, assembly plate and locking element, and secure.
  2.  
  3. Inspect the cylinder head gasket and oil pan gasket and replace if necessary.
  4.  
  5. Replace the front crankshaft seal in the timing chain cover if necessary.
  6.  
  7. Install all ancillary components to timing case cover previously removed.
  8.  
  9. Apply sealant to the marked surfaces with a bead thickness of 1-2 mm.
    NOTE
    Install the timing cover within 10 minutes after applying sealant. Do not spread the sealant bead.



    Click image to see an enlarged view

    Fig. Apply sealant (2) to the marked surfaces of the timing chain cover (1) with a bead thickness of 1-2 mm-2.7L Engine

  10.  
  11. Do not seal the pressurized oil galleries to the crankcase. Sealant applied at these points is entrained by the oil flow and blocks the oil supply passages.
  12.  
  13. Position and install the timing chain cover. Tighten the bolts to 15 ft. lbs. (20 Nm).
  14.  
  15. Install the M8 bolts of cylinder head-to-timing chain front cover and tighten bolts to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the timing chain tensioner with a new seal.
  18.  
  19. Position and install the oil pan. For additional information, refer to the following section, -Oil Pan, Removal & Installation.-
  20.  
  21. Install the crankshaft vibration damper. Tighten the bolts to 240 ft. lbs. (325 Nm) plus 90°.
  22.  
  23. Remove the engine support fixture.
  24.  
  25. Install the alternator.
  26.  
  27. Install the air conditioning compressor.
  28.  
  29. Install the power steering pump.
  30.  
  31. Install the water pump.
  32.  
  33. Connect coolant hose to oil-water heat exchanger.
  34.  
  35. Install the high pressure fuel pump.
  36.  
  37. Apply sealant to the lower portion of, and install, front cover to cylinder block. Tighten the bolts to 15 ft. lbs. (20Nm).
  38.  
  39. Remove the retaining lock for crankshaft/starter ring gear.
  40.  
  41. Tighten the oil drain plug to 22 ft. lbs. (30 Nm).
  42.  
  43. Install a new oil filter and tighten the screw cap for the filter to 18 ft. lbs. (25 Nm).
  44.  
  45. Install the accessory drive belt.
  46.  
  47. Install the radiator assembly.
  48.  
  49. Install the air intake assembly.
  50.  
  51. Refill the cooling system to the correct level.
  52.  
  53. Refill the engine with oil to the correct level.
  54.  
  55. Connect the negative battery cable.
  56.  
  57. Start the engine and check for leaks.
  58.  

3.0L Engines
  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.  
  67. Make sure that the timing marks on the back of the camshafts are horizontal and pointing at each other.
  68.  
  69. Remove the timing chain tensioner.
    NOTE
    Cover the timing chain area. Care must be taken not to drop any repair debris or pieces into the engine when separating the timing chain links.

  70.  
  71. Install Special Tool 9554 using two of the cylinder head cover bolts.
  72.  
  73. Assemble Special Tool 9312-1 using 9312-3 and 9312-4. Install Insert 9312-13 and retain with screw provided.
    CAUTION
    Care must be taken not to drop the timing chain plates into the engine once the timing chain is separated.


    NOTE
    When installing Special Tool 9312-1 onto timing chain link, be sure to back off the smaller nut of the Thrust Pin 9312-3 until the pin is recessed inside of the spindle, 9312-4. Screw the Thrust Spindle 9312-4 in until it is seated and aligned properly over the rivet of the timing chain.


    NOTE
    When fitting the thrust spindle, ensure that the thrust pin is positioned at the left timing chain pin of a chain link.


    NOTE
    Cover the timing chain area. Care must be taken not to drop any repair debris or pieces into the engine when separating the timing chain links.

  74.  
  75. Carefully turn the thrust pin 9312-13 of Special Tool 9312-1 clockwise while holding the handle until the rivet is pressed out and the chain is separated. Discard the loose link and plates.
  76.  
  77. Use a small screwdriver to prevent the timing chain from slipping into the engine.
    NOTE
    One whole timing chain link must be removed.

  78.  

To install:

  1. Connect a new timing chain with the oil holes facing up, and old timing chain with the assembly link, assembly plate and locking element, and secure.
  2.  
  3. Install the front crankshaft seal in the timing cover.
  4.  
  5. Install the timing cover and tighten bolts to 80 inch lbs. (9 Nm).
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Install the front oil pan bolts and tighten the bolts to 88 inch lbs. (10 Nm).
  10.  
  11. Lower the vehicle.
  12.  
  13. Install the vibration damper and pulley. Tighten the bolt to 154 ft. lbs. (210 Nm) plus 180°.
  14.  
  15. Install the accessory drive belt tensioner. Tighten bolt to 43 ft. lbs. (58 Nm).
  16.  
  17. Install the idler pulleys and tighten the bolts to 20 ft. lbs. (28 Nm).
  18.  
  19. Install the accessory drive belt.
  20.  
  21. Install the EGR air control valve assembly.
  22.  
  23. Install the glow plug module.
  24.  
  25. Install the charge air outlet tube.
  26.  
  27. Install the cooling fan module. Tighten upper bolts to 10 ft. lbs. (14 Nm).
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. Remove Special Tool 9102 Crankshaft Lock.
  32.  
  33. Install the starter blank.
  34.  
  35. Install the lower cooling fan module bolts and tighten the lower bolts to 10 ft. lbs. (14 Nm).
  36.  
  37. Install the power steering line between the retainer and cooling fan module.
  38.  
  39. Connect the cooling fan wiring harness connector.
  40.  
  41. Install the power steering hose between the cooling fan and suspension.
  42.  
  43. Install the power steering hose between the pump and cooling fan.
  44.  
  45. Install the front skid plate.
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the hoses at the power steering reservoir.
  50.  
  51. Refill the power steering reservoir to the correct level.
  52.  
  53. Install the front engine cover bracket.
  54.  
  55. Install the engine cover.
  56.  
  57. Refill the cooling system to the correct level.
  58.  
  59. Refill the engine with oil to the correct level.
  60.  
  61. Connect the negative battery cable.
  62.  
  63. Purge the air from the power steering system before starting by raising the vehicle and rotating the steering wheel back and forth 20 times.
  64.  
  65. Start the engine and follow the bleed procedure with the scan tool.
  66.  
  67. Turn engine off and inspect for leaks.
  68.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil
  6.  
  7. Remove the engine appearance cover.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Turn the engine to 40 degrees after Top Dead Center (TDC).
  12.  
  13. Install the crankshaft locking tool.
  14.  
  15. Remove the lower splash shield.
  16.  
  17. Remove the lower bolt to the engine oil dipstick tube.
  18.  
  19. Lower the vehicle.
  20.  
  21. Remove the grille.
  22.  
  23. Remove the cooling module.
  24.  
  25. Remove the PCM.
  26.  
  27. Remove the engine harness.
  28.  
  29. Remove the upper oil dipstick tube bolt.
  30.  
  31. Remove the oil dipstick and oil dipstick tube.
  32.  
  33. Remove the intake manifold.
  34.  
  35. Remove the air pump.
  36.  
  37. Remove the lower and upper oil pan.
  38.  
  39. Remove the accessory drive belt.
  40.  
  41. Remove the thermostat housing.
  42.  
  43. Remove the thermostat gasket.
  44.  
  45. Remove the accessory drive belt tensioner assembly.
  46.  
  47. Remove the oil filter/cooler housing.
  48.  
  49. Remove the idler pulley.
  50.  
  51. Remove the crankshaft damper bolt.
  52.  
  53. Remove the crankshaft damper pulley.
  54.  
  55. Remove the water pump and gasket.
  56.  
  57. Remove the left front cylinder head cover.
  58.  
  59. Remove the right side air control valve.
  60.  
  61. Remove the right air control valve gasket.
  62.  
  63. Remove the upper right front cylinder head cover.
  64.  
  65. Remove the left air control valve and gasket.
  66.  
  67. Remove the left air control valve adapter and gasket.
  68.  
  69. Remove and position aside the power steering pump.
  70.  
  71. Remove and position aside the AC compressor.
  72.  
  73. Remove the alternator.
  74.  
  75. Remove the cylinder head covers.
  76.  
  77. Remove the timing chain tensioner.
  78.  
  79. Install a drift into the camshaft to lock the split gears.
  80.  
  81. Remove the timing chain guide (2, 3) roll pins from the right cylinder head.
  82.  
  83. Remove the center valve bolts (1, 4 ) from the camshafts.
    NOTE
    The intake camshaft adjuster bolts are a left-hand thread. The exhaust camshaft bolts are a right-hand thread.


    NOTE
    Support the timing chain to prevent it from falling off the crankshaft or balance shaft.



    Click image to see an enlarged view

    Fig. Remove the timing chain guide (2,3) roll pins and center valve bolts (1,4) from the camshafts-3.5L engine front cover removal

  84.  
  85. Remove the camshaft adjusters.
  86.  
  87. Remove the cylinder head to front cover bolts in the left cylinder head.
  88.  
  89. Remove the cylinder head to front cover bolts in the right cylinder head.
    NOTE
    The front cover bolts have several different sizes. Note the locations of each bolt.



    Click image to see an enlarged view

    Fig. The cylinder head-to-front cover bolts must be removed in each cylinder head-3.5L Engine

  90.  
  91. Remove the front cover bolts.
  92.  
  93. Remove the front cover.
  94.  
  95. Remove the timing chain tensioner.
  96.  
  97. Use a slide hammer to remove the slide rail pins in the left and right cylinder head.
  98.  
  99. Remove the oil pump chain.
  100.  
  101. Remove the timing chain slide rails.
  102.  
  103. Insert a drift into left camshaft adjuster.
  104.  
  105. Insert a drift into the right camshaft adjuster.
  106.  
  107. Remove the camshaft adjuster from the left cylinder head.
  108.  
  109. Remove the camshaft adjuster from the right cylinder head.
  110.  
  111. Disconnect the timing chain links.
  112.  
  113. Remove the timing chain.
  114.  

To install:

  1. Make sure that the drift is installed into the camshaft adjuster.
  2.  
  3. Align the pin with the hole in the end of the camshaft to install the camshaft adjuster on the intake camshaft.
  4.  
  5. When the camshaft is correctly aligned on the camshaft adjuster, the alignment marks on the back of the camshaft adjuster will be lined up and the camshaft will seat all of the way into the adjuster.
  6.  
  7. Install the intake and exhaust camshafts into the cylinder head so that the horizontal alignment marks line up with the top edge of the cylinder head and the vertical alignment mark is pointed upwards.
  8.  
  9. Align the slot in the balance shaft with the mark on the cylinder head (the mark is at about the 2 o'clock position).
  10.  
  11. Replace any timing chain guides with excessive wear.
  12.  
  13. Install all of the timing chain guides.
  14.  
  15. Install the timing chain guide pins.
  16.  
  17. Feed one end of the timing chain into the left cylinder head.
  18.  
  19. Feed the timing chain through the engine and around the balance shaft.
  20.  
  21. Draw the timing chain up through the right cylinder head and over the right cylinder head intake camshaft.
  22.  
  23. Feed the chain down through the cylinder head to the crankshaft sprocket.
  24.  
  25. Draw the timing chain up through the left cylinder head.
  26.  
  27. Assemble the chain using a new link.
  28.  
  29. Remove the drift from the left camshaft adjuster.
  30.  
  31. Install a new camshaft timing wheel on the intake camshaft in the left cylinder head. Rotate the timing wheel until the wheel sits flush on the camshaft. There is a dimple in the camshaft and a matching dimple in the timing wheel. Make sure that the camshaft timing wheel dimples line up.
  32.  
  33. Install the left camshaft adjuster center bolt finger tight.
  34.  
  35. Remove the drift from the right camshaft adjuster.
  36.  
  37. Install a new camshaft timing wheel on the intake camshaft in the right cylinder head. Rotate the timing wheel until the wheel sits flush on the camshaft. There is a dimple in the camshaft and a matching dimple in the timing wheel. Make sure that the camshaft timing wheel dimples line up.
  38.  
  39. Install the right camshaft adjuster center bolt finger tight.
  40.  
  41. Make sure the front cover o-rings at the water pump inlet and outlet are intact and in place.
  42.  
  43. Turn the balance shaft so that the timing mark on the balance shaft matches the timing mark on the engine block.
  44.  
  45. Make sure the timing chain is correctly mounted to the crankshaft and balance shaft sprockets.
  46.  
  47. Install the front cover and tighten the bolts in a crisscross pattern to 15 ft. lbs. (20 Nm).
  48.  
  49. Tighten the cylinder head-to-front cover bolts to 11 ft. lbs. (15 Nm) plus an additional 90°.
  50.  
  51. Coat the end of the camshafts with a small amount of oil.
  52.  
  53. Line up the pin in the camshaft adjusters with the hole in the camshafts.

    Click image to see an enlarged view

    Fig. After coating the end of the camshaft (1) with oil, line up the pin in the camshaft adjusters (4) with the hole in the camshafts (2)-3.5L Engine

  54.  
  55. The camshaft pulse wheel must be replaced every time it is removed. The dimples in the pulse wheel must line up with the depressions in the camshaft adjusters.
  56.  
  57. Make sure that the crankshaft is set to 40° After Top Dead Center (ATDC), and that the crankshaft lock is installed.
  58.  
  59. When the crankshaft adjusters are correctly installed, the timing marks will line up with each other and the top mark will be pointed up.
  60.  
  61. Install the timing chain onto the left cylinder head intake camshaft adjuster.
  62.  
  63. Install the camshaft adjuster to the intake camshaft in the left cylinder head.
  64.  
  65. Install the camshaft adjuster to the exhaust camshaft in the left cylinder head. Make sure the timing marks line up correctly.
  66.  
  67. Install the slide rails.
  68.  
  69. Install the timing chain on the right cylinder head intake camshaft adjuster.
  70.  
  71. Install the right cylinder head camshaft adjuster to the intake camshaft.
  72.  
  73. Install the right cylinder head exhaust camshaft adjuster.
  74.  
  75. Verify that the intake camshafts are correctly timed to the crankshaft position.
  76.  
  77. Install the center valves into the left and right cylinder head camshafts and tighten to 106 ft. lbs. (145 Nm).
  78.  
  79. Remove the drift from the camshafts.
  80.  
  81. Reset the timing chain tensioner by removing the end of the tensioner assembly.
  82.  
  83. Remove the sealing ring from the tensioner assembly.
  84.  
  85. Remove the spring and pin from the tensioner assembly.
  86.  
  87. Replace the pin into the back of the tensioner assembly, followed by the spring, dowel, sealing ring, and tensioner end.
  88.  
  89. Tighten the end of the tensioner to 36 ft. lbs. (50 Nm).
  90.  
  91. Install the timing chain tensioner and tighten to 51 ft. lbs. (70 Nm).
  92.  
  93. Apply silicone to the cylinder head cover sealing surfaces and install the left and right cylinder head covers. Tighten the cylinder head cover bolts to 106 inch lbs. (12 Nm) plus an additional 90°. For additional information, refer to the following section, "Cylinder Head, Removal & Installation.-
  94.  
  95. Install the power steering pump.
  96.  
  97. Install the AC compressor.
  98.  
  99. Install the left air control valve adapter gasket and adapter. Tighten the left air control valve adapter bolts to 10 ft. lbs. (14 Nm).
  100.  
  101. Install the left air control valve gasket and control valve. Tighten the left air control valve bolts to 10 ft. lbs. (14 Nm).
  102.  
  103. Apply a bead of silicone to the cylinder head front cover sealing surface.
  104.  
  105. Install the left front cylinder head cover and tighten the front cover bolts in a cross pattern to 70 inch lbs. (8 Nm).
  106.  
  107. Apply a bead of silicone to the cylinder head front cover sealing surface.
  108.  
  109. Install the upper right front cylinder head cover and tighten the front cover bolts in a cross pattern to 70 inch lbs. (8 Nm).
  110.  
  111. Install the right air control valve gasket and control valve. Tighten the mounting bolts to 10 ft. lbs. (14 Nm).
  112.  
  113. Install the water pump gasket and water pump. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  114.  
  115. Install the water pump pulley. Tighten the water pump pulley M7 bolts to 88 inch lbs. (10 Nm) and then to 18 ft. lbs. (25 Nm). Tighten the water pump pulley M8 bolts to 44 inch lbs. (5 Nm) and then to 15 ft. lbs. (20 Nm).
  116.  
  117. Install the crankshaft damper pulley and tighten to 147 ft. lbs. (200 Nm) plus 90°.
  118.  
  119. Install the idler pulley and tighten the bolts to 26 ft. lbs. (35 Nm).
  120.  
  121. Install the oil filter/cooler housing and tighten the housing bolts to 15 ft. lbs. (20 Nm).
  122.  
  123. Install the thermostat gasket, and install the thermostat housing. Tighten the bolts to 18 ft. lbs. (25 Nm).
  124.  
  125. Install the accessory drive belt tensioner assembly and tighten the bolts to 25 ft. lbs. (35 Nm).
  126.  
  127. Install the accessory drive belt.
  128.  
  129. Install the air pump.
  130.  
  131. Install the intake manifold.
  132.  
  133. Install the engine harness.
  134.  
  135. Install the PCM.
  136.  
  137. Raise and safely support the vehicle.
  138.  
  139. Remove the crankshaft lock.
  140.  
  141. Install the starter.
  142.  
  143. Install the alternator.
  144.  
  145. Install the upper and lower oil pans.
  146.  
  147. Install the oil dipstick and oil dipstick tube. Tighten the mounting bolt to 80 inch lbs. (9 Nm).
  148.  
  149. Install the lower splash shield.
  150.  
  151. Lower the vehicle.
  152.  
  153. Install the cooling module.
  154.  
  155. Install the grille.
  156.  
  157. Refill the cooling system to the correct level.
  158.  
  159. Refill the engine with oil to the correct level.
  160.  
  161. Install the engine appearance cover.
  162.  
  163. Connect the negative battery cable.
  164.  
  165. Start the engine and check for leaks.
  166.  

 
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