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Cover(S), Engine Timing: Installation: Installation

Fig 1: Coolant Outlet Housing, Water Pump & Bolts
GC0144267Courtesy of CHRYSLER LLC
  1. If removed, install the coolant outlet housing (1) to the timing cover with a new gasket using only the four bolts (2) shown in illustration tightened to 12 N.m (106 in. lbs.).
  2. If removed, install the water pump (3) to the timing cover using only the four bolts (4) shown in illustration tightened to 12 N.m (106 in. lbs.). Refer to PUMP, WATER, INSTALLATION .
    Fig 2: Coolant Outlet Housing Gasket & Water Pump Gasket
    GC0144266Courtesy of CHRYSLER LLC
  3. Install the coolant outlet housing gasket (1) and the water pump gasket (2).
    Fig 3: Sealant At Cylinder Head Bosses, Right & Left Flanges, Cylinder Head-To-Engine Block T-Joints & Cover To Right Cam Chain Tensioner Gap
    GC0144268Courtesy of CHRYSLER LLC
  4. Clean the engine timing cover, cylinder head and block mating surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Threebond Engine RTV Sealant may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Threebond Engine RTV Sealant to the gasket surfaces, the components must be assembled within 20 minutes and the attaching fasteners must be tightened to specification within 45 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  5. Apply a 2 to 3 mm wide bead of Mopar® Threebond Engine RTV Sealant to the front cover as shown in illustration in the following locations:
    • Three cylinder head bosses (1)
    • Right and left flanges (2)
    • Four cylinder head to engine block T-joints (3)
    • Cover to right cam chain tensioner gap (4)
    Fig 4: Locating Timing Cover Attaching Bolts & Locator Pins
    GC0144966Courtesy of CHRYSLER LLC
  6. Align the locator pins (5) on the engine block to the engine timing cover and install the cover.
    NOTE:

    The bolt (4) could be M6 (early production) or M8 (late production).

  7. Install and tighten the timing cover attaching bolts:
    • Twenty-two M6 bolts (3) to 12 N.m (106 in. lbs.).
    • One M8 bolt (2) to 25 N.m (18 ft. lbs.).
    • Three M10 bolts (1) to 55 N.m (41 ft. lbs.).
    • One M6 (early production) or M8 (late production) bolt (4). Tighten the M6 bolt to 12 N.m (106 in. lbs.) or tighten the M8 bolt to 25 N.m (18 ft. lbs.).
    Fig 5: Lower Oil Pan & Fasteners
    GC0145008Courtesy of CHRYSLER LLC
  8. Install the upper and lower oil pans. Refer to PAN, OIL, INSTALLATION .
    Fig 6: Cylinder Head Cover Mounting Bolts & Stud bolts
    GC0144198Courtesy of CHRYSLER LLC
    NOTE:

    Left cylinder head cover shown in illustration, right cylinder head cover similar.

  9. Install the right and left cylinder head covers and upper intake manifold. Refer to COVER(S), CYLINDER HEAD, INSTALLATION .
    Fig 7: Idler Pulley, Tensioner Arm, Belt, Idler, Tensioner & Belt
    GC0144013Courtesy of CHRYSLER LLC
  10. Install the crankshaft vibration damper (6). Refer to DAMPER, VIBRATION, INSTALLATION .
  11. Install the accessory idler pulley (2). Refer to PULLEY, IDLER, INSTALLATION .
  12. Install accessory drive belt tensioner (7). Refer to TENSIONER, BELT, INSTALLATION .
  13. Install the accessory drive belt (3). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 8: Heater Core Supply Tube Support Bracket & Retaining Bolt
    GC0144401Courtesy of CHRYSLER LLC
  14. Install the heater core supply tube (1) with one bolt (2) tightened to 12 N.m (106 in. lbs.).
    Fig 9: Heater Core Supply Hose & Coolant Outlet Housing
    GC0144272Courtesy of CHRYSLER LLC
  15. Install the heater core supply hose (1) to the coolant outlet housing (2).
    Fig 10: Radiator Hose & Heater Hose
    GC0144271Courtesy of CHRYSLER LLC
  16. Install the lower radiator hose (2) to the water pump housing.
  17. Install the heater core return hose (1) to the water pump housing.
    Fig 11: Upper Radiator Hose & Thermostat Housing
    GC0144270Courtesy of CHRYSLER LLC
  18. Install the thermostat housing (1) and upper radiator hose (2). Refer to THERMOSTAT, REMOVAL .
  19. Install the electric vacuum pump. Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
  20. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to Engine/Lubrication/OIL - Standard Procedure .
  21. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  22. Fill the cooling system. Refer to STANDARD PROCEDURE .
  23. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
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