2002 Chrysler Intrepid BaseFACTORY OEM SERVICE PROCEDURE

Timing Chain Cover: Installation

  1. Inspect and clean sealing surfaces. Inspect and replace gasket and seal as necessary.
  2. If front crankshaft seal was bench installed, place Special Tool 6780-2, Sleeve over crankshaft nose to guide and protect seal lip.
  3. Before installing timing cover gasket apply a 1/8 inch bead of Mopar® Engine RTV GEN II to the parting lines between the oil pan and cylinder block (Fig 1).
    Fig 1: Applying Sealant To Timing Chain Cover
    G00990850Courtesy of DAIMLERCHRYSLER CORP.
  4. Install timing cover and gasket. Tighten M10 cover bolts to 54 N.m (40 ft. lbs.) and M6 bolts to 12 N.m (105 in. lbs.) (Figure).
  5. If not previously performed, install crankshaft oil seal using Special Tool 6780-2 sleeve and 6780-2 installer.
  6. Install crankshaft vibration damper. (Refer to VIBRATION DAMPER )
  7. Attach power steering pump to bracket.
  8. Install A/C belt tensioner assembly to timing cover.
  9. Install generator/power steering drive belt tensioner pulley and bracket.
  10. Install radiator fan (Refer to RADIATOR FAN ASSEMBLY )
  11. Install accessory drive belts. (Refer to DRIVE BELTS - 2.7L )
  12. Install radiator upper crossmember. (Figure)
    1. Place in position the radiator upper crossmember.
    2. Connect hood latch cable to hood latch.
    3. Install bolts attaching upper radiator closure panel. Check bolt alignment marks.
    4. Install bolts attaching the forward edge of upper radiator closure panel.
    5. Install fasteners attaching the forward edge of radiator upper crossmember.
    6. Install fasteners attaching upper bumper fascia.
    7. Install fasteners attaching upper bumper fascia.
    8. Install headlamp jackscrews both sides.
    9. Check hood operation.
  13. Connect negative cable.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.