OEM 2003 Dodge Sprinter 2500 Timing Cover

2003 Dodge Sprinter 2500 Timing Cover Parts and Q&A

• Q: How to Remove and Install a Timing Cover on 2003 Dodge Sprinter 2500?

  A: You should begin by removing the battery cable from the negative terminal and place the engine at ignition TDC for cylinder 1, making sure the markings on the camshaft cap are aligned. Eliminate the coolant and oil, then pull out the oil filter to have the oil gather in the pan. After that, disconnect the radiator assembly, engine cover, front cover at the cylinder head, accessory drive belt, high pressure fuel pump, water pump, accessory drive belt pulley, vibration damper and power steering pump, but do not open the air conditioning system. Drop the AC compressor out of the compressor mount, unplug the electrical connector and install it in the lower area of the engine compartment. Disconnect the wires from the generator and bring it over to the engine compartment. Following that, install the engine support fixture, unlatch the oil pan, unclip the coolant cycle to the heat exchanger on the crankcase and remove the bolts of the cylinder head to the timing cover. Remove the timing cover, cut all the bolts and any element secured to it, while checking both hoses and clamps for harm. Get rid of the timing chain tensioner and the timing case cover. For installation, look over the cylinder head gasket and oil pan gasket and change them if they appear damaged and also replace the front crankshaft seal. Fit the additional parts for the timing case cover, cover the parts the sealant is meant for with a 1.5 ± 0.5 mm bead and place the timing case cover inside within 10 minutes of applying sealant, with 20 Nm of torque. Rotate the M8 bolts of the cylinder head into the timing case cover and tighten them to 20 Nm, then attach the timing chain tensioner with a new seal as well. Place the oil pan in position and screw its M6 bolts to 9 Nm and its M8 bolts to 20 Nm. Set up the belt/pulley vibration damper by screwing in the M8.8 bolt to 200 Nm at first, then to 90° next. Screw in the M10.9 bolt to 325 Nm at first and then 90°. Get rid of the engine support fixture, put in the generator, air conditioning compressor, power steering pump and water pump. Bring the coolant hose to the oil-water heat exchanger, install the high pressure fuel pump, apply sealant beneath the front cover, place assemblies firmly against the cylinder block and tighten bolts at 20 Nm. Untighten the retaining lock for the crankshaft/starter ring gear, close the oil drain plug to 30 Nm and screw on the new oil filter cap until the torque shows 25 Nm. Fix the drive belt to the accessory, assemble the radiator and attach the air intake hose. Then, add the right liquids to both the coolant and crankcase. At the final step, link the negative battery terminal, start the engine and keep an eye out for leaks while noticing warning signs from the fuel system.