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Timing Chain Cover: Installation

WARNING: This page is about a different variant/trim than selected.
NOTE: Ensure all sealing surfaces have been cleaned and prepared properly for effective repair. Multi-Layer Steel (MLS) gaskets require a scratch free sealing surface.
Fig 1: Removing/Installing Cylinder Head Bolts
GC0034763Courtesy of DAIMLERCHRYSLER CORP.
  1. Install the cylinder heads, and install the bolts (1). (Refer to ENGINE/CYLINDER HEAD - INSTALLATION) .
    Fig 2: Rotating Crankshaft To 40° ATDC
    GC0034760Courtesy of DAIMLERCHRYSLER CORP.
  2. Align the basic valve timing to 40 deg. ATDC. (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
    Fig 3: Applying Sealer
    GC0034754Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Apply sealer ONLY to the area marked (1) as shown. If porous points are visible at the cylinder heads or at the rear of the engine near the sealing surface of the cylinder head gasket, apply sealant at these points. The sealant must be applied only as a 2.0 mm +/- 0.5 mm bead, assembled within 10 minutes, and not be flattened or spread.
  3. Apply a 1.5 to 2.0 mm bead of Loctite 5203 or equivalent sealer to the area marked (1) as shown.
  4. Position the timing chain cover on the front of the engine.
    Fig 4: Applying Thread Sealer To Indicated Bolts
    GC0034753Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly.
  5. Install the timing chain cover bolts and tighten to 20 N.m (15 ft. lbs.).
    Fig 5: Removing/Installing Timing Chain Tensioner
    GC0034755Courtesy of DAIMLERCHRYSLER CORP.
  6. Install the timing chain tensioner (1), tighten to 80 N.m (59 ft. lbs.). (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN TENSIONER&PULLEY - INSTALLATION) .
    Fig 6: Removing/Installing Special Tool 9102
    GC0034756Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
  8. Install the starter. (Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION) .
  9. Install a new front crankshaft radial oil seal. (Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION) .
  10. Install the generator. (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
    Fig 7: Removing/Installing Vibration Damper
    GC0034766Courtesy of DAIMLERCHRYSLER CORP.
  11. Install the vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) .
  12. Install the idler pulley. (Refer to COOLING/ACCESSORY DRIVE/IDLER PULLEY - INSTALLATION) .
    Fig 8: Identifying Return Hose & Pressure Hose
    GC0034764Courtesy of DAIMLERCHRYSLER CORP.
  13. Install the power steering pump, return hose (1), and pressure hose (2). (Refer to STEERING/PUMP - INSTALLATION) .
    Fig 9: Identifying Lower Oil Pan
    GC0034765Courtesy of DAIMLERCHRYSLER CORP.
  14. Install the upper and lower (1) oil pan. (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION) .
    Fig 10: Routing Accessory Drive Belt
    GC0034762Courtesy of DAIMLERCHRYSLER CORP.
  15. Install the accessory drive belt. (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
    Fig 11: Removing Engine
    GC0034759Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the engine from the stand.
  17. Install the clutch if equipped. (Refer to CLUTCH/CLUTCH DISC - INSTALLATION) .
  18. Install the transmission on the engine. (Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) or (Refer to TRANSMISSION/TRANSAXLE/AUTOMATIC - NAG1 - INSTALLATION) .
  19. Install the engine in the vehicle. (Refer to ENGINE - INSTALLATION) .
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