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Friday, April 20, 2012

Dodge Sprinter 3.5L Engine Timing Chain Replacing?

How to replace Timing Chain.The complete procedure with diagrams.

The details for Dodge Sprinter Van/ Truck Models.
The 3.5L Engine.

The procedure starts Here.


Timing Chain & Sprockets Removal/ installation:---


  1. Disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Drain the engine oil
  4. Remove the engine appearance cover.
  5. Raise and safely support the vehicle.
  6. Turn the engine to 40 degrees after Top Dead Center (TDC).
  7. Install the crankshaft locking tool.
  8. Remove the lower splash shield.
  9. Remove the lower bolt to the engine oil dipstick tube.
  10. Lower the vehicle.
  11. Remove the grille.
  12. Remove the cooling module.
  13. Remove the PCM.
  14. Remove the engine harness.
  15. Remove the upper oil dipstick tube bolt.
  16. Remove the oil dipstick and oil dipstick tube.
  17. Remove the intake manifold.
  18. Remove the air pump.
  19. Remove the lower and upper oil pan.
  20. Remove the accessory drive belt.
  21. Remove the thermostat housing.
  22. Remove the thermostat gasket.
  23. Remove the accessory drive belt tensioner assembly.
  24. Remove the oil filter/cooler housing.
  25. Remove the idler pulley.
  26. Remove the crankshaft damper bolt.
  27. Remove the crankshaft damper pulley.
  28. Remove the water pump and gasket.
  29. Remove the left front cylinder head cover.
  30. Remove the right side air control valve.
  31. Remove the right air control valve gasket.
  32. Remove the upper right front cylinder head cover.
  33. Remove the left air control valve and gasket.
  34. Remove the left air control valve adapter and gasket.
  35. Remove and position aside the power steering pump.
  36. Remove and position aside the AC compressor.
  37. Remove the alternator.
  38. Remove the cylinder head covers.
  39. Remove the timing chain tensioner.
  40. Install a drift into the camshaft to lock the split gears.
  41. Remove the timing chain guide (2, 3) roll pins from the right cylinder head.
  42. 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.


    image
    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
  43. Remove the camshaft adjusters.
  44. Remove the cylinder head to front cover bolts in the left cylinder head.
  45. 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.


    image
    Fig. The cylinder head-to-front cover bolts must be removed in each cylinder head-3.5L Engine
  46. Remove the front cover bolts.
  47. Remove the front cover.
  48. Remove the timing chain tensioner.
  49. Use a slide hammer to remove the slide rail pins in the left and right cylinder head.
  50. Remove the oil pump chain.
  51. Remove the timing chain slide rails.
  52. Insert a drift into left camshaft adjuster.
  53. Insert a drift into the right camshaft adjuster.
  54. Remove the camshaft adjuster from the left cylinder head.
  55. Remove the camshaft adjuster from the right cylinder head.
  56. Disconnect the timing chain links.
  57. Remove the timing chain.
To install:
  1. Make sure that the drift is installed into the camshaft adjuster.
  2. Align the pin with the hole in the end of the camshaft to install the camshaft adjuster on the intake camshaft.
  3. 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.
  4. 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.
  5. Align the slot in the balance shaft with the mark on the cylinder head (the mark is at about the 2 o'clock position).
  6. Replace any timing chain guides with excessive wear.
  7. Install all of the timing chain guides.
  8. Install the timing chain guide pins.
  9. Feed one end of the timing chain into the left cylinder head.
  10. Feed the timing chain through the engine and around the balance shaft.
  11. Draw the timing chain up through the right cylinder head and over the right cylinder head intake camshaft.
  12. Feed the chain down through the cylinder head to the crankshaft sprocket.
  13. Draw the timing chain up through the left cylinder head.
  14. Assemble the chain using a new link.
  15. Remove the drift from the left camshaft adjuster.
  16. 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.
  17. Install the left camshaft adjuster center bolt finger tight.
  18. Remove the drift from the right camshaft adjuster.
  19. 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.
  20. Install the right camshaft adjuster center bolt finger tight.
  21. Make sure the front cover o-rings at the water pump inlet and outlet are intact and in place.
  22. Turn the balance shaft so that the timing mark on the balance shaft matches the timing mark on the engine block.
  23. Make sure the timing chain is correctly mounted to the crankshaft and balance shaft sprockets.
  24. Install the front cover and tighten the bolts in a crisscross pattern to 15 ft. lbs. (20 Nm).
  25. Tighten the cylinder head-to-front cover bolts to 11 ft. lbs. (15 Nm) plus an additional 90°.
  26. Coat the end of the camshafts with a small amount of oil.
  27. 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
  28. 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.
  29. Make sure that the crankshaft is set to 40° After Top Dead Center (ATDC), and that the crankshaft lock is installed.
  30. When the crankshaft adjusters are correctly installed, the timing marks will line up with each other and the top mark will be pointed up.
  31. Install the timing chain onto the left cylinder head intake camshaft adjuster.
  32. Install the camshaft adjuster to the intake camshaft in the left cylinder head.
  33. Install the camshaft adjuster to the exhaust camshaft in the left cylinder head. Make sure the timing marks line up correctly.
  34. Install the slide rails.
  35. Install the timing chain on the right cylinder head intake camshaft adjuster.
  36. Install the right cylinder head camshaft adjuster to the intake camshaft.
  37. Install the right cylinder head exhaust camshaft adjuster.
  38. Verify that the intake camshafts are correctly timed to the crankshaft position.
  39. Install the center valves into the left and right cylinder head camshafts and tighten to 106 ft. lbs. (145 Nm).
  40. Remove the drift from the camshafts.
  41. Reset the timing chain tensioner by removing the end of the tensioner assembly.
  42. Remove the sealing ring from the tensioner assembly.
  43. Remove the spring and pin from the tensioner assembly.
  44. Replace the pin into the back of the tensioner assembly, followed by the spring, dowel, sealing ring, and tensioner end.
  45. Tighten the end of the tensioner to 36 ft. lbs. (50 Nm).
  46. Install the timing chain tensioner and tighten to 51 ft. lbs. (70 Nm).
  47. 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.-
  48. Install the power steering pump.
  49. Install the AC compressor.
  50. Install the left air control valve adapter gasket and adapter. Tighten the left air control valve adapter bolts to 10 ft. lbs. (14 Nm).
  51. Install the left air control valve gasket and control valve. Tighten the left air control valve bolts to 10 ft. lbs. (14 Nm).
  52. Apply a bead of silicone to the cylinder head front cover sealing surface.
  53. Install the left front cylinder head cover and tighten the front cover bolts in a cross pattern to 70 inch lbs. (8 Nm).
  54. Apply a bead of silicone to the cylinder head front cover sealing surface.
  55. Install the upper right front cylinder head cover and tighten the front cover bolts in a cross pattern to 70 inch lbs. (8 Nm).
  56. Install the right air control valve gasket and control valve. Tighten the mounting bolts to 10 ft. lbs. (14 Nm).
  57. Install the water pump gasket and water pump. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  58. 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).
  59. Install the crankshaft damper pulley and tighten to 147 ft. lbs. (200 Nm) plus 90°.
  60. Install the idler pulley and tighten the bolts to 26 ft. lbs. (35 Nm).
  61. Install the oil filter/cooler housing and tighten the housing bolts to 15 ft. lbs. (20 Nm).
  62. Install the thermostat gasket, and install the thermostat housing. Tighten the bolts to 18 ft. lbs. (25 Nm).
  63. Install the accessory drive belt tensioner assembly and tighten the bolts to 25 ft. lbs. (35 Nm).
  64. Install the accessory drive belt.
  65. Install the air pump.
  66. Install the intake manifold.
  67. Install the engine harness.
  68. Install the PCM.
  69. Raise and safely support the vehicle.
  70. Remove the crankshaft lock.
  71. Install the starter.
  72. Install the alternator.
  73. Install the upper and lower oil pans.
  74. Install the oil dipstick and oil dipstick tube. Tighten the mounting bolt to 80 inch lbs. (9 Nm).
  75. Install the lower splash shield.
  76. Lower the vehicle.
  77. Install the cooling module.
  78. Install the grille.
  79. Refill the cooling system to the correct level.
  80. Refill the engine with oil to the correct level.
  81. Install the engine appearance cover.
  82. Connect the negative battery cable.
  83. Start the engine and check for leaks.



The following help links are provided to complete this Timing chain removal tasks:---

How to Replace water pump on Dodge Sprinter?

Procedure to replace Dodge Sprinter Thermostat?

http://fordrepairhelp.blogspot.in/2012/04/procedure-to-replace-dodge-sprinter.html


Replace Dodge Sprinter Engine Cooling Fan?

How to replace Radiator on Dodge Sprinter?

2.7L Timing Chain Replacing on Dodge Sprinter?

How to replace Timing chain and Sprockets on Dodge Sprinter?



These details will help.
Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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