1999 Dodge Intrepid Primary Timing Chain & Sprockets Replacement.pdf

1999 Dodge Intrepid Primary Timing Chain & Sprockets Replacement

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NOTE: Before removing primary timing chain, check timing drive system wear limits. See INSPECTION . CAUTION: Before removing crankshaft pulley, ensure A/C belt tensioner is not contacting crankshaft pulley. Removal 1. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Using Crankshaft Pulley Holder (8191), hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley. 2. Remove upper intake manifold. See INTAKE MANIFOLD . Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers. Remove power steering pump and set aside.

Remove drive belt tensioner pulley and bracket. Remove timing chain cover. CAUTION: DO NOT turn camshaft. Rotate engine by turning crankshaft. 3. Align crankshaft sprocket timing mark to mark on oil pump housing. Mark on oil pump housing is 60 degrees ATDC of number one cylinder. See Fig. 10 . CAUTION: When timing chain is removed and cylinder heads are installed, DO NOT rotate camshafts or crankshaft without first locating proper crankshaft position. 4. Remove primary timing chain tensioner from right cylinder head. Remove camshaft position sensor from left cylinder head. Remove chain guide access plug from left cylinder head. See Fig. 11 . 5. Remove right camshaft sprocket bolts and sprocket.

When camshaft sprocket bolts are removed, camshaft will rotate clockwise. Remove left side camshaft sprocket attaching bolts and sprocket. Remove lower chain guide and tensioner arm. Remove primary timing chain. Inspection Remove right valve cover. Looking through cylinder head timing drive cavity, inspect primary chain tensioner plunger. Rotate engine clockwise to remove any chain slack and to achieve maximum tensioner extension. If maximum wear indicator groove (machined groove) on plunger is visible, timing chain and/or related components are worn or stretched to service limits. See Fig. 12 . Inspect all sprockets, tensioners and chain guides. Replace as necessary.