QuestionMy son's 2000 Dodge Intrepid (2.7L) with 60K mi. has a bad timing chain tensioner. The car lost power while driving at about 30mph. It restarted but barely ran (idle, but no power to move). Upon disassembly, I discovered that the timing chain had slipped by a few teeth. What are the chances that my engine is not ruined? If I replace the tensioner, set the timing, and perform a compression check with good results can I assume that we dodged a bullet? As a side question, can you tell me if there's any secret to removing the tensioner? I removed the retaining bolt but can't get the tensioner out of its hole. Thanks for any help/advice you can give.
AnswerHi Alan,
A few teeth slippage may not be so much as to have driven a piston into a valve, so I would try to reset the timing. It is a pretty long and involved process. Fortunately Kevin, another Chrysler expert, has access to on-line manuals and replied similarly to another owner of that engine as follows:
TIMING CHAIN AND SPROCKETS
REMOVAL
Remove upper intake manifold. Refer to procedure in this section.
Remove cylinder head covers, crankshaft damper, and timing chain cover. Refer to procedures in this section
CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.
Align crankshaft sprocket timing mark to mark on oil pump housing Timing Mark Alignment The mark on oil pump housing is 60° ATDC of #1 cylinder
CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.
Remove primary timing chain tensioner from right cylinder head Primary Timing Chain Tensioner
Remove camshaft position sensor from left cylinder head Primary Timing Drive System
Remove chain guide access plug from left cylinder head Primary Timing Drive System
NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.
Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper and sprocket Primary Timing Drive System
Remove left side camshaft sprocket attaching bolts and remove sprocket Primary Timing Drive System
Remove lower chain guide and tensioner arm Primary Timing Drive System
Remove the primary timing chain.
INSTALLATION
Inspect all sprockets and chain guides. Replace if worn. Refer to crankshaft sprocket, for removal and installation procedures in this section.
If removed, install right and left side short chain guides Primary Timing Drive System Tighten attaching bolts to 28 N·m (250 in. lbs.)
Align crankshaft sprocket timing mark to the mark on oil pump housing Primary Timing Chain Marks
NOTE: Lubricate timing chain and guides with engine oil before installation.
Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links Primary Timing Chain Marks
Lower the primary chain with left side sprocket through the left cylinder head opening
NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.
Loosely position left side camshaft sprocket over camshaft hub.
Align timing (plated) link to the crankshaft sprocket timing mark Primary Timing Chain Marks
Position primary chain onto water pump drive sprocket.
Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain Primary Timing Chain Marks and loosely position over camshaft hub.
Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets Primary Timing Chain Marks
Install left side lower chain guide and tensioner arm Primary Timing Drive System Tighten attaching bolts to 28 N·m (250 in. lbs.)
NOTE: Inspect oil ring on chain guide access plug before installing. Replace O-ring as necessary.
Install chain guide access plug to left side cylinder head Primary Timing Drive System Tighten plug to 20 N·m (15 ft. lbs.)
NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner Timing Chain Tensioner - Oil Purging
Purge oil from timing chain tensioner using the following procedure:
Place the check ball end of tensioner into the shallow end of Special Tool 8186 Timing Chain Tensioner - Oil Purging
Using hand pressure, slowly depress tensioner until oil is purged from tensioner Timing Chain Tensioner - Oil Purging
Reset timing chain tensioner using the following procedure:
Position cylinder plunger into the deeper end of Special Tool 8186 Timing Chain Tensioner - Resetting
Apply a downward force until tensioner is reset Timing Chain Tensioner - Resetting
NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.
CAUTION: Ensure the tensioner is properly reset. The tensioner body must bottom against the top edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.
Install the reset chain tensioner into the right cylinder head Primary Timing Chain Tensioner
Position tensioner retaining plate and tighten bolts to 12 N·m (105 in. lbs.) Primary Timing Chain Tensioner
Starting at the right cylinder bank, insert a 3/8" square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 N·m (250 in. lbs.) Primary Timing Chain Marks
Turn the left side camshaft by inserting a 3/8" square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 N·m (250 in. lbs.) Primary Timing Chain Marks
Rotate engine slightly clockwise to remove timing chain slack, if necessary.
To arm the timing chain tensioner: Use a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly Timing Chain Tensioner Arming Then, release the tensioner arm. Verify the tensioner is armed (extends)
Install the timing chain cover, crankshaft damper, and cylinder head covers.
Install camshaft position sensor and connect electrical connector.
Install upper intake manifold. Refer procedure in this section
NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5 - 10 seconds
It would be helpful to you to have the 6 or so pages from the manual that shows the process. I will be glad to xerox copy and postal mail them to you. Just use the "thank and rate" tab where there is a section for comments where you can give your postal mailing address to me. If you you would be so kind as to send me back three 41 cent stamps that would cover my copy costs and postage.
Roland
