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Timing Chain Cover

Fig 1: Timing Cover Bolt Location
GC0064458Courtesy of CHRYSLER LLC
1,7 - BOLT - M8 x 1.25 x 80 4 - BOLT - M10 x 1.5 x 85
2 - BOLT - M10 x 1.5 x 85 5 - BOLT - M8 x 1.25 x 80
3 - BOLT - M8 x 1.25 x 80 6 - BOLT - M10 x 1.5 x 85
CAUTION: Crankshaft oil seal must be removed to insure correct oil pump engagement.
  1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.
    NOTE: DO NOT USE SEALER ON COVER GASKET
  2. Position new gasket on timing cover. Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is 0.5 mm (0.020 in.) beyond the lower edge of the cover.
  3. Rotate crankshaft so that the oil pump drive flats are in the vertical position.
  4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats.
    CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.
  5. Install timing cover.
    NOTE: Torque the M10 bolts (2,4,6,) first, then the M8 (1,3,5,7).
  6. Install timing chain cover bolts. Tighten the M10 bolts (2,4,6) to 54 N.m (40 ft. lbs.) and M8 bolts (1,3,5,7) to 28 N.m (21 ft. lbs.).
    Fig 2: 3.8 Oil Pressure Switch
    GC0064414Courtesy of CHRYSLER LLC
  7. Install the oil pan. See INSTALLATION .
  8. Install crankshaft front oil seal. See INSTALLATION .
  9. Install crankshaft vibration damper. See INSTALLATION .
  10. Install a new oil filter (2) and connect the oil pressure switch (1).
    Fig 3: Camshaft Position Sensor 3.8L
    GC0064459Courtesy of CHRYSLER LLC
  11. Connect the coolant hoses.
  12. Install camshaft position sensor (CMP).
    Fig 4: Generator Mounting 3.8L
    GC0064460Courtesy of CHRYSLER LLC
  13. Install A/C compressor.
  14. Install the oil level indicator tube.
  15. Install the generator (3).
    Fig 5: Mounting Bolts
    GC0064461Courtesy of CHRYSLER LLC
  16. Install the power steering pump (1).
  17. Install the accessory drive belt and idler pulley.
  18. Fill crankcase with engine oil to proper level.
    Fig 6: Inlet Air Temperature Sensor 3.8L
    GC0064462Courtesy of CHRYSLER LLC
  19. Install the Air cleaner housing and hose (1).
  20. Fill cooling system.
  21. Connect negative cable to battery.
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