Chrysler 4892138AB Cover-Timing Case

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Caution is advised as the timing system is complex, and mistakes can lead to severe engine damage; only highly experienced individuals should attempt this procedure, and consulting an expert is recommended if there is any uncertainty. Double-check all work to ensure correctness before starting the engine, and do not rotate the crankshaft or camshafts separately during this process to avoid valve damage. Several special tools are necessary, so ensure they are obtained beforehand. Begin by relieving fuel system pressure and disconnecting the negative battery cable, then loosen the lug nuts on the right front wheel, raise the vehicle, and support it securely. Drain the engine coolant and oil, remove the right-front wheel and drive-belt splash shield, and take off the engine cover. For 2015 and later models, also remove the intake tube and air filter housing, and position the coolant expansion tank aside. Remove the drivebelt, tensioner, and idler pulleys, then position the number one piston at Top Dead Center. For 2014 and earlier models, remove the power steering fluid reservoir without disconnecting the lines, and secure it out of the way. Remove the crankshaft pulley, ignition coils, and valve cover, taking care not to let the magnetic timing wheels come into contact with any magnets. Remove the water pump pulley and, for 2014 and earlier models, the air conditioning compressor and bracket. Remove specific oil pan bolts as instructed, support the engine, and remove the right-side engine mount and its bracket. Take out the timing cover mounting bolts, carefully pry the cover free, and clean off any RTV gasket material. If the engine has moved from TDC, temporarily install the crankshaft pulley bolt and align the timing marks. For 2014 and earlier models, align the timing chain plated links with the camshaft phaser timing marks, ensuring proper alignment of the phaser or sprocket marks with the plated links. Inspect the timing chain dampener for wear, clean the timing chain and sprockets, and replace them if necessary. Before starting the engine, rotate the crankshaft by hand to check for resistance. Remove old gasket material from all components, install the crankshaft sprocket and oil pump chain if removed, and ensure the keyway is at TDC. Coat the sprockets and chain with clean engine oil, align the chain with the camshaft sprockets, and install the camshaft sprocket. Hold the timing chain tensioner in place, install the chain guide and tensioner, and verify the alignment of all marks after rotating the engine. Apply RTV sealant to the timing cover sealing surfaces, install the cover, and tighten the bolts in a criss-cross pattern. Complete the installation by reversing the removal steps, adding oil and coolant, and starting the engine to check for leaks.

The timing is precise; an error is costly, damaging the engine beyond repair in the process. This procedure should only be done by highly technical personnel and any doubt, consultation with a specialist is recommended. Recheck all works before starting the engine. Excessive movement of the crank shaft or cam shafts should not be done at this stage as this may cause further damage to the valves. A number of specialised implements are used to perform these procedures; make sure they are procured before operation commences. First, remove the negative battery terminal, and then cap the fuel injectors and exhaust and evaporative system, then remove the right-front wheel, lower the vehicle properly as much as possible, and finally drain the engine coolant and oil. Unbolt the right-front wheel and the drive-belt splash shield, then unlock the drivebelt, tensioner and idler pulley. Then, it is required to take off the thermostat housing, upper radiator hose and heater hose from the water pump and shift the heater core supply pipe aside. The two magnetic timing wheels should not come in contact with these magnets; so remove the power steering pump, crankshaft pulley, and valve covers. Lift the upper and lower oil pans, set the engine mount crossmember in place temporarily and raise the engine to take out the right mount and bracket. Loosen and pull out the timing cover fasteners and, if required, pry out the cover; also, discard the coolant housing and water pump seals. As a preparation, screw in loosely the crankshaft pulley bolt and with the crankshaft at TDC number 1 on the exhaust stroke, align the timing marks. Check whether the camshaft phaser marks are aligned, and phaser marks with the plated links, if they are not aligned. Insert the first and second tensioners in, if not already done so, push down the tensioner plungers, next, the timing gear splash shield can now be removed, and after that the oil pump tensioner and sprocket. Insert the camshaft phaser lock tools into position, depower the locks of the oil control valves, and come out the camshaft phasers and the timing chains. Check timing chain dampener for wear and tear and clean the timing chain as well as the sprockets replacing them if required. In addition, always turn the crankshaft manually at least two complete turns in the direction of crankshaft rotation before the start of the engine and there should be an opposition to the efforts used. There will also be need to replace the gasket material and sealant used previously as well as fitting of the chain guides and tensioners together with the keyway on the crankshaft. Locate the primary chain on the crankshaft sprocket, apply some clean engine oil on the sprockets and the chain before fitting the assembly in such a manner that they are lined up with the correct alignment marks. Fasten the idler sprocket and then fit the primary chain guide and tensioner, also fit the left and right side camshaft phasers and oil control valves in correct positions. The oil pump timing chain, its tensioner, the sprocket and splash shield are to be bolted into place and at the same time confirming that the marks tally with each other. Later, rotate the engine with your hands again to confirm the alliance of the marks. Replace the coolant housing and water pump housing gaskets, apply silicone based RTV sealant on the cover and fit it onto the alignment dowels. Screw in the cover bolts in the correct direction and then make sure you do it in an x or a crossing manner. After that, you can proceed to perform the removal process in the reverse order. Last but not least, pour oil and more coolant, turn on the engine and look for signs of leakage.

To remove the components, first, you have to unclamp the negative battery cable from the battery. Subsequently, the serpentine drivebelt should be pulled off and the coolant drained and the water pump pulley should be unbolted. Lift the vehicle with jack and put the jackstands in order and then, drain the engine oil of the vehicle. Place the engine and the transaxle in the lift with the help of a floor jack and support it with a block of wood on the left side of the car. Remove the engine mount nearest to the timing cover end on the right side of the engine. Go further and take out the oil pan and oil pump pick-up tube and then unbolt the right wheel and inner splash cover. Loosen the bolts of idler pulley and disconnect it, remove the mounting plate of the engine by removing the bolts. Remove the ac compressor from its mounted position and place it aside - use of mechanic wire is recommended as it may be required in another position in the working area. First, the drivebelt tensioner has to be unscrewed from the engine; second, the cam sensor from the timing cover. Remove the canister purge hose at the fenderwell area, also unscrew the timing cover to engine block bolts, this shall be done while noting the positions of the bolts. When possible use a copper gasket scraper to remove entirely all the old gasket material and sealant that adheres to the cover and the engine block and ensure one does not scratch the aluminum cover. To install place a thin layer of RTV sealant on both side of the new gasket and then the gasket is placed on the engine block, followed by the cover on which the crankshaft oil pump gear must fit appropriately. Each of the engaged bolts has to be tightened in a staggered class pattern in three steps to the prescribed torque. Last, undo all the measures employed, put oil and coolant in as a final topping, switch on the engine and begin checking for any signs of leakage.

Remove the right-front wheel and drive-belt splash shield, followed by the drivebelt, tensioner, and idler pulley. Next, remove the thermostat housing, upper radiator hose, and heater hose from the water pump, then move the heater core supply pipe out of the way.

Yes, for 2015 and later models, also remove the intake tube and air filter housing, and position the coolant expansion tank aside.