C. Replace Cylinder Head Core Plugs
1. Remove the crankshaft damper center bolt and remove the crankshaft damper (Figure 24).
2. Remove the power steering pump bracket.
3. Remove the lower timing belt cover (Figure 25).
4. Remove the upper front timing belt cover (Figure 25).
5. Remove the upper rear timing belt cover (Figure 25).
6. Mark the timing belt running direction for later reference (Figure 26).
7. Set the engine timing to TDC (Figure 27).
8. Remove the timing belt auto tensioner (Figure 27).
9. Remove the timing belt from the camshaft sprockets.
10. Remove the front and rear camshaft sprockets by holding the sprocket with Special Tool 6847, removing the bolt and washer and then removing the sprocket (Figure 28).
11. Remove the core plug (behind the camshaft sprocket) from the front and rear cylinder head as follows:
^ Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the core plug (Figure 29).
^ With the core plug rotated, grasp it firmly with pliers or another suitable tool and remove the plug.
CAUTION:
Do not drive the core plug into the casting as restricted cooling can result and cause serious cooling problems.
12. Install a new core plug into the front and rear cylinder head (behind camshaft sprocket) as follows:
^ Thoroughly remove all rust and clean the inside of the core plug hole in the cylinder head. Be sure to remove all of the old sealer.
^ Lightly coat the side of the new core plug with a sealer such as Mopar Gasket Maker (PN 4318083).
^ Using the proper sized plug driver or socket, drive the plug into the hole so that the sharp edge of the plug is between 0.020" - 0.040" (0.5 mm - 1.0 mm) inside the lead in chamfer (Figure 29).
13. Install the front and rear camshaft sprockets. Tighten the sprocket bolts to 65 ft-lbs (88 N.m) while holding the sprocket with Special Tool 6847 (Figure 28).
14. Place the timing belt tensioner into a vice and slowly compress the plunger (Figure 30).
NOTE:
Be sure to index the tensioner in the vice in the same way that it is installed on the engine. This is to ensure proper pin orientation when the tensioner is installed on the engine.
15. Install a pin through the tensioner body to retain the plunger in the compressed position (Figure 30).
16. Make sure the crankshaft sprocket is set to TDC by aligning the sprocket with the mark on the oil pump housing. Then back it off to 3 notches before TDC (Figure 31).
17. Set the camshaft sprockets to the aligning marks on the rear timing belt cover (Figure 32).
18. Rotate the crankshaft to TDC (Figure 33).
19. Install the timing belt on the rear camshaft sprocket first. Install a binder clip on the belt and sprocket so that the belt will not slip out of position.
IMPORTANT:
Make sure that the belt is oriented in the direction that was previously marked on the belt.
20. Keeping the belt taught, install it under the water pump pulley and then around the front camshaft sprocket. Install another binder clip on the belt and front camshaft sprocket.
21. Make sure that the timing belt is still routed around the idler pulley, around the crankshaft pulley and the past the tensioner pulley (Figure 33). Make sure that all timing marks are aligned.
22. Install the auto tensioner and tighten the tensioner bolts to 204 in-lbs (23 N.m).
23. Remove the pin from the tensioner.
24. Rotate the crankshaft two (2) revolutions in a clockwise direction only and then check the alignment of the timing marks. Check the tensioner by inserting the pin into the tensioner hole. The pin should slide in and out freely. Remove the pin.
25. Install the upper rear, upper front and lower timing belt covers (Figure 25). Tighten the larger cover bolts to 150 in-lbs (17 N.m). Tighten the smaller cover bolts to 105 in-lbs (12 N.m).
26. Install the crankshaft damper (Figure 24). Tighten the damper bolt to 134 ft-lbs (182 N.m).
NOTE:
Do not install the power steering pump bracket at this time.
27. Continue with Section "D" -- Replace Cylinder Block Core Plugs.