Service Procedure
A. Domestic Vehicles (North American Built)1. IMPORTANT: Inspect vehicle for engine build code, shown on label located on cylinder head cover. Only those engines with build codes 7215, 7216, 7217 or 7218 are defective. All such engines must be repaired, as detailed in the following steps.
CAUTION NOTE: Engines which do not have one of the listed build codes are not to be repaired. The modified plungers could cause low oil pressure in these engines which could damage them. For vehicles with these engines, no further action is required.
FOR VEHICLES REQUIRING REPAIR, proceed as follows:
2. Disconnect battery.
3. Drain and save engine coolant for reinstallation following completion of repairs.
4. Remove engine chain case cover. This requires prior removal of parts in the following order, to provide access to the chain case cover:
a. Air cleaner air horn: Detach from carburetor and set aside.
b. Fuel flow sensor (if so equipped): Detach from cylinder head cover.
c. Fuel line: Detach from carburetor.
d. Carburetor support (carburetor-to-cylinder head cover): Remove.
e. Water pump pulley cover: Remove.
f. Distributor cap and wires: Detach and set aside.
g. Hoses routed above cylinder head cover: Detach and set aside to clear cylinder head cover.
h. Cylinder head cover: Remove. Discard semi-circular packing from right end of cylinder head.
i. Distributor: Remove.
j. Two attachment bolts, cylinder head-to-chain case cover (forward of cam sprocket): Remove.
FIGURE 1:
Service Procedure
A. Domestic Vehicles (Continued)
4. k. Carburetor air duct (on passenger cars only): Remove. (See Figure 1.)
l. Alternator and belt(s): Remove.
m. Power steering pump belt (if soequipped): Remove.
FIGURE 2:
n. Mount engine support fixture to vehicle with end brackets resting in fender-to-inner shield channel areas. (See Figure 2.) Attach and adjust support to engine at right (passenger side) rear lifting-eye location.
o. Raise vehicle on hoist.
p. Drain engine oil, replacing plug when drained.
q. Right front wheel and inner splash shield: Remove.
r. Air conditioner compressor (if so-equipped): Remove (4) bolts attaching compressor to mounting brackets. With compressor still attached to refrigerant lines, move compressor out of the way toward the vehicle right front corner. Support the compressor in this temporary position to avoid damaging refrigerant lines.
FIGURE 3:
Service Procedure
A. Domestic Vehicles (Continued)
4. s. Right engine mount lower attaching nut. Remove. (See Figure 3.)
t. Lower hoist to support vehicle at floor level.
u. Right engine mount: Remove remaining attachments from engine and side rail (Figure 3) and remove engine mount.
v. Right engine mounting plate:
Detach from chain case cover and remove.
w. Raise vehicle on hoist.
x. Crankshaft pulley: Remove.
y. Timing indicator bracket and alternator-to-chain case cover bracket: Remove.
z. Oil pan: Remove. aa. Chain case cover: Remove. Take care not to damage cylinder head gasket.
FIGURE 4:
5. IMPORTANT: Rotate engine crankshaft until timing marks on all
(3) silent shaft chain sprockets are aligned with the corresponding timing marks on the silent shaft chain. The timing marks on the sprockets are the punch marks on the teeth while those on the chain are the plated links. (See Figure 4.)
6. Remove silent shaft chain guide "B" (Figure 4).
Service Procedure
A. Domestic Vehicles (Continued)
7. Remove upper silent shaft sprocket. With the chain still engaged to the lower (2) sprockets, move the upper portion of chain to provide tool access for the oil pump relief valve plug.
FIGURE 5:
8. Remove oil pump bolt as indicated in Figure 5 for tool access to relief valve.
9. Remove oil pump relief valve plug, using a 22 mm short socket or wrench. (See Figure 5.) If using a socket, use care to avoid bearing against or damaging camshaft timing chain tensioner. A 3/8 -drive breaker - bar is recommended for improved access.
10. Remove relief valve spring. Remove plunger (Figure 5), using a pencil-magnet. Discard plunger.
11. Install replacement plunger (supplied). Check for smooth movement of plunger for entire length of bore, using the pencilmagnet. Reinstall original spring and plug. Tighten plug to a torque of 25 foot-pounds.
12. Clean gasket surfaces for reassembly of chain case cover, oil pan and cylinder head cover.
13. Reassemble all parts in reverse order to the disassembly procedure. Refer to the Service Manual for torque values.
The following steps are required during reassembly:
^ When reassembling the silent shaft chain, be sure that the timing marks on all
(3) sprockets and corresponding chain links are aligned.
FIGURE 6:
Service Procedure (Continued)
A. Domestic Vehicles (Continued)
13. ^ When reassembling silent shaft chain guide "B," the supplied spring washer must be installed between the upper attachment of chain guide "B" and the mating hole on the camshaft timing chain guide. (See Figure 6.)
FIGURE 7:
^ Adjust the silent shaft chain tension as follows (see Figure 7):
- Shake oil pump and silent shaft sprockets to collect chain slack between sprockets.
- Adjust the position of chain guide B so that when the chain is pulled in the direction of arrow F with finger tips, the clearance between chain guide B and the chain links will be 1 to 3.5 mm (.04 to .14 in .). Tighten chain guide B mounting screws.
^ Coat new chain case cover gaskets (supplied) with MOPAR Spray Gasket 160 Sealer, Part Number 4318035, or equivalent.
^ Be sure to reinstall two bolts fastening cylinder head to top of chain case cover before reinstalling cylinder head cover.
^ Rotate crank so that No. 1 piston is at TDC on compression stroke. Then align marks on distributor drive gear and adjacent distributor housing before installing distributor.
^ Coat top of semi-circular packing with above sealant before cylinder head cover installation.
Service Procedure
B. Imported Vehicles (MMC Built)
1. IMPORTANT: All imported vehicles included in this service action have engines with the previously listed build codes and must be repaired.
For repair, the service procedure is the same as that of domestic vehicles except certain other components must be removed to provide access for chain case cover removal. These are described in the following steps.
2. Disconnect battery.
3. Drain and save engine coolant for reinstallation following completion of repairs.
4. Remove components for chain case cover access as follows:
a. Air cleaner/air intake tube: To clear cylinder head cover.
b. Distributor cap and wires: Detach and set aside.
c. Linkage, hoses, lines: Detach and set aside as needed to clear cylinder head cover.
d. Secondary air cleaner assembly (Conquest only): Detach and move to clear cylinder head cover.
e. Cylinder head cover: Remove. Discard semi-circular packing from front end of cylinder head.
f. Distributor: Remove.
g. Two attachment bolts, cylinder head-to-chain case cover (forward of cam sprocket): Remove.
h. Fan and water pump pulley: Remove.
i. Radiator (and shroud if so equipped): Remove.
j. Belts -- air conditioner compressor (if so equipped), alternator/water pump, power steering (if so equipped): Remove.
k. Raise vehicle on hoist.
l. "Under Cover" (stone/skid shield beneath oil pan): Remove.
m. Alternator: Remove.
Service Procedure
B. Imported Vehicles (Continued)
4.
n. Air conditioner compressor (if so equipped): Remove (5) bolts between mounting brackets and engine. (The brackets may remain attached to the compressor). With compressor still attached to refrigerant lines, move compressor out of the way toward the left (driver's) side of vehicle. Support the compressor in this temporary position to avoid damaging refrigerant lines.
o. Power steering pump (if so equipped): Disconnect and move to side.
p. Drain engine oil, replacing plug when drained.
q. Oil pan: Remove.
r. Lower hoist.
s. Water pump hoses: Disconnect at water pump.
t. Crankshaft pulley: Remove.
u. Chain case cover: Remove. Take care not to damage cylinder head gasket.
NOTE: Remaining steps are the same as for domestic vehicles. Proceed to Service Procedure Section A, Steps 5-13 for completion of repair.