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Home >> Chrysler >> 2007 >> Crossfire Base, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 74 (3.5L Engine (Service Information)) >> Valve Timing >> Front Cover >> Installation
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Front Cover: Installation

WARNING: This page is about a different car, the 2008 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Front Cover Removed
GC0066234Courtesy of CHRYSLER LLC
NOTE: Make sure that all sealing surfaces on the engine are clean and free of oil.
  1. Make sure the front cover o-rings at the water pump inlet and outlet are intact and in place.
  2. Turn the balance shaft so that the timing mark on the balance shaft matches the timing mark on the engine block.
  3. Make sure the timing chain is correctly mounted to the crankshaft and balance shaft sprockets.
  4. Install the front cover.
  5. Install the front cover bolts. Use a cross pattern to tighten the front cover bolts to 20 N.m (177 in. lbs.).
    Fig 2: Cylinder Head To Front Cover Bolts
    GC0066265Courtesy of CHRYSLER LLC
  6. Install the cylinder head to front cover bolts (1) in the right cylinder head.
  7. Tighten the cylinder head to front cover bolts to 15 N.m (132 in. lbs.) and then an additional 90 degrees.
    Fig 3: Cylinder Head To Timing Case Bolts
    GC0066208Courtesy of CHRYSLER LLC
  8. Install the cylinder head to front cover bolts (1) in the left cylinder head.

    Tighten the cylinder head to front cover bolts to 15 N.m (132 in. lbs.) and then an additional 90 degrees.

    Fig 4: Lining Up The Pin In The Camshaft Adjusters With The Hole In The Camshafts
    GC0066266Courtesy of CHRYSLER LLC
  9. Coat the end of the camshafts (1) with a small amount of oil.
  10. Line up the pin in the camshaft adjusters (4) with the hole in the camshafts (2).
    Fig 5: Adjuster Pin Locations
    GC0066267Courtesy of CHRYSLER LLC
  11. The camshaft pulse wheel must be replaced every time it is removed. The dimples in the pules wheel must line up with the depressions in the camshaft adjusters.
    Fig 6: Camshaft And Crankshaft Timing And TDC
    GC0066191Courtesy of CHRYSLER LLC
  12. Make sure that the crankshaft is set to 40° ATDC, and that the crankshaft lock is installed.
  13. When the crankshaft adjusters are correctly installed, the timing marks (4) will line up with each other and the top mark (3) will be pointed up.
  14. Install the timing chain onto the left cylinder head intake camshaft adjuster.
  15. Install the camshaft adjuster to the intake camshaft in the left cylinder head.
  16. Install the camshaft adjuster to the exhaust camshaft in the left cylinder head. Make sure the timing marks line up correctly.
    Fig 7: Slide Rails
    GC0066247Courtesy of CHRYSLER LLC
  17. Install the slide rails (3).
  18. Install the timing chain on the right cylinder head intake camshaft adjuster.
  19. Install the right cylinder head camshaft adjuster to the intake camshaft.
  20. Install the right cylinder head exhaust camshaft adjuster.
  21. Verify that the intake camshafts are correctly timed to the crankshaft position.
    NOTE: The center valves in the exhaust camshafts are L. H. thread. The center valves in the intake camshafts are R.H. thread.
  22. Install new CMP plates.
  23. Install the center valves into the left (1) and right (4) cylinder head camshafts.
  24. Tighten the camshaft adjuster center valves to 145 N.m (106 ft. lbs.).
    Fig 8: Installing The Camshaft Adjuster
    GC0066211Courtesy of CHRYSLER LLC
  25. Remove the drift (3) from the camshafts.
    Fig 9: Exploded View Of Timing Chain Tensioner
    GC0066201Courtesy of CHRYSLER LLC
  26. Reset the timing chain tensioner by removing the end (1) of the tensioner assembly.
  27. Remove the sealing ring from the tensioner assembly (2).
  28. Remove the spring (3) and (4) pin from the tensioner assembly.
  29. Replace the pin (8) into the back of the tensioner assembly, followed by the spring (3), dowel (4), sealing ring (2), and tensioner end (1).
  30. Tighten the end of the tensioner (1) to 50 N.m (36 ft. lbs.)
  31. Install the timing chain tensioner and tighten to 70 N.m (51 ft. lbs.)
    Fig 10: Cylinder Head Cover And Bolts
    GC0066214Courtesy of CHRYSLER LLC
  32. Apply silicone to the cylinder head cover sealing surface.
  33. Install the right cylinder head cover.
  34. Install the left cylinder head cover.
  35. Use the illustrated pattern to tighten the cylinder head cover bolts to 12 N.m (106 in. lbs.) and then an additional 90 degrees.
    Fig 11: Left ACV Gasket - Lower
    GC0066264Courtesy of CHRYSLER LLC
  36. Install the power steering pump. Refer to INSTALLATION .
  37. Install the AC compressor. Refer to INSTALLATION .
  38. Install the left air control valve adapter gasket.
    Fig 12: Left ACV Gasket - Upper
    GC0066263Courtesy of CHRYSLER LLC
  39. Install the left air control valve adapter. Tighten the left air control valve adapter bolts to 14 N.m (143 in. lbs.)
  40. Install the left air control valve gasket.
    Fig 13: Left ACV
    GC0066262Courtesy of CHRYSLER LLC
  41. Install the left air control valve. Tighten the left air control valve bolts to 14 N.m (143 in. lbs.)
    Fig 14: Left Front Cylinder Head Cover
    GC0066206Courtesy of CHRYSLER LLC
  42. Apply a bead of silicone to the cylinder head front cover sealing surface.
  43. Install the left front cylinder head cover (1).
  44. Tighten the front cover bolts in a cross pattern to 8 N.m (70 in. lbs).
    Fig 15: Right Upper Front Cylinder Head Cove
    GC0066199Courtesy of CHRYSLER LLC
  45. Apply a bead of silicone to the cylinder head front cover sealing surface.
  46. Install the upper right front cylinder head cover (1).
  47. Tighten the front cover bolts in a cross pattern to 8 N.m (70 in. lbs).
    Fig 16: Air Control Valve Gasket - Right
    GC0066215Courtesy of CHRYSLER LLC
  48. Install the right air control valve gasket.
    Fig 17: Air Control Valve Bolts - Right
    GC0066197Courtesy of CHRYSLER LLC
  49. Install the right side air control valve.
  50. Install the right air control valve bolts.
  51. Tighten the bolts to 14 N.m (123 in. lbs).
    Fig 18: Water Pump Gasket
    GC0066261Courtesy of CHRYSLER LLC
  52. Install the water pump gasket.
    Fig 19: Water Pump Pulley And Bolts
    GC0066259Courtesy of CHRYSLER LLC
  53. Install the water pump.
  54. Tighten the water pump bolts in a cross pattern to 25 N.m (221 in. lbs.).
    Fig 20: Oil Filter/Cooler Housing, Idler Pulley, Vibration Damper Bolt And Crankshaft Damper
    GC0066246Courtesy of CHRYSLER LLC
  55. Install the water pump pulley (6).
  56. Install the water pump pulley bolts (5).
  57. Tighten the water pump pulley M7 bolts to 10 N.m (88 in. lbs.) and then to 25 N.m (221 in. lbs.).
  58. Tighten the water pump pulley M8 bolts to 5 N.m (44 in. lbs.) and then to 20 N.m (220 in. lbs.).
  59. Install the crankshaft damper pulley (3).
  60. Install the crankshaft damper bolt (4) and tighten to 200 N.m (147 ft. lbs.) and then an additional 90 degrees.
  61. Install the idler pulley (1).
  62. Tighten the idler pulley bolts to 35 N.m (26 ft. lbs.)
    Fig 21: Oil Cooler Housing
    GC0066268Courtesy of CHRYSLER LLC
  63. Install the oil filter/cooler housing (2).
  64. Use the illustrated pattern to tighten the oil filter/cooler housing (2) bolts to 20 N.m (15 ft. lbs.).
    Fig 22: Thermostat Gasket
    GC0066256Courtesy of CHRYSLER LLC
  65. Install the thermostat gasket.
    Fig 23: Removing/Installing Thermostat
    GC0066222Courtesy of CHRYSLER LLC
  66. Install the thermostat housing and tighten the bolts to 25 N.m (220 in. lbs).
    Fig 24: Accessory Drive Belt Bolt
    GC0066190Courtesy of CHRYSLER LLC
  67. Install the accessory drive belt tensioner assembly and tighten the bolts to 35 N.m (25 ft. lbs.).
  68. Install the accessory drive belt.
    Fig 25: Air Pump And Vacuum Pump
    GC0066196Courtesy of CHRYSLER LLC
  69. Install the air pump (5).
  70. Install the intake manifold. See INSTALLATION .
    Fig 26: PCM
    GC0066173Courtesy of CHRYSLER LLC
  71. Install the engine harness.
  72. Install the PCM.
    Fig 27: Crankshaft Locking Tool
    GC0066245Courtesy of CHRYSLER LLC
  73. Raise the vehicle.
  74. Remove the crankshaft lock.
  75. Install the starter. Refer to INSTALLATION .
    Fig 28: Generator
    GC0066180Courtesy of CHRYSLER LLC
  76. Install the generator. Refer to INSTALLATION .
    Fig 29: Upper Oil Pan Bolts
    GC0066231Courtesy of CHRYSLER LLC
  77. Install the upper oil pan. See INSTALLATION .
    Fig 30: Lower Oil Pan
    GC0066243Courtesy of CHRYSLER LLC
  78. Install the lower oil pan. See INSTALLATION .
    Fig 31: Dipstick Tube Bolt
    GC0066253Courtesy of CHRYSLER LLC
  79. Install the oil dipstick and oil dipstick tube.
  80. Install the lower bolt to the engine oil dipstick tube.
  81. Install the upper oil dipstick tube bolt and tighten to 9 N.m (80 in. lbs).
    Fig 32: Remote Ground
    GC0066161Courtesy of CHRYSLER LLC
  82. Install the lower splash shield.
  83. Lower the vehicle.
  84. Connect the remote battery ground.
  85. Fill the coolant. Refer to STANDARD PROCEDURE .
  86. Fill the engine oil. Refer to SPECIFICATIONS .
    Fig 33: Fan Shroud Assembly
    GC0066192Courtesy of CHRYSLER LLC
  87. Install the cooling module. Refer to INSTALLATION .
    Fig 34: Grill Assembly
    GC0066187Courtesy of CHRYSLER LLC
  88. Install the grille (1).
    Fig 35: Intake Air Housing
    GC0066163Courtesy of CHRYSLER LLC
  89. Install the engine cover.
  90. Close the hood.
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