C3940462 is available at the national depot (list $260, national depot
usually sends second day air), C3940461 is available at several regional
depots (list $108). Either parts kit has your oil pump, plus the other
stuff for whichever recall applies to your car.

NO.:499, 521 
March, 1992

To:All Dodge Dealers

Subject:Customer Satisfaction Notification # 499 -- Turbo III
Lubrication, PCV Hose and Crankshaft Timing Sprocket

Customer Satisfaction Notification # 521 -- Turbo III Lubrication

Models: # 499: 1991 Model Year Dodge Spirit RT (AA-Body)
Equipped With 2.2L DOHC Turbo III Engine -- Vehicles Built
From Job # 1 Through October 22, 1990

 # 521: 1991 Model Year Dodge Spirit RT (AA-Body) Equipped
 With 2.2L DOHC Turbo III Engine -- Vehicles Built From
 October 23, 1990 Through End Of Model Year


The engine oil pump drive gear on vehicles involved in
both Customer Satisfaction Notifications # 499 and # 521
may fail due to excessive stress on the gear teeth. To correct
the condition, a revised oil pump and intermediate shaft must be
installed in all vehicles. Also, the turbo oil drain-back hose
will be replaced, an insulator will be added to the hose, and a
new stone guard will be installed for the right (passenger side)
engine mount.

In addition, for the small number of vehicles in notification
# 499 only, 2 other conditions require correction:

The vehicles were built with an orifice in the PCV vacuum hose
which may allow water to enter and freeze in the hose, causing
positive crankcase pressure. A hose without an orifice must be installed.

The crankshaft timing sprocket may fail. This steel sprocket must
be replaced with a cast sprocket.

Important:
Some of the involved vehicles may still be in dealer stock. Be
sure to complete the service on these vehicles before retail delivery.

Details of this service action are explained in the following sections.

Note:
No videotape of the service procedure for this recall will be provided.


Important:  No parts will be distributed in advance for this service
requirement. Dealers must order as needed for vehicles to be repaired.

For service of involved vehicles, order the proper parts package for #
499 or # 521 as required. Package descriptions and components are as
follows:

Notification Recall Quantity Description Number Pkg. PN

# 499 C3940462
 (1) Crankshaft timing sprocket

 (1) PCV hose

 (1) Intermediate shaft

 (1) Oil pump assembly

 (1) Oil drain-back hose

 (1) Drain-back hose insulator

 (1) GStone guard

 (1) GOil pan gasket set

 (5) Screw, crankshaft pulley

 (1) Clip, 02 sensor wiring

 (1) Clip, 02 sensor wiring connector

 (1) Instruction summary


Notification  Recall  Quantity  Description
 Number Pkg. PN

 # 521 C3940461 (1) Intermediate shaft

 (1) Oil pump assembly

 (1) Oil drain-back hose

 (1) Drain-back hose insulator

 (1) Stone guard

 (1) Oil pan gasket set

 (1) Clip, 02 sensor wiring

 (1) Clip, 02 sensor wiring connector

 (1) Instruction summary

 Note:  In addition to a parts package, the following special tools
 will be required to perform the service procedure:

 Recall # 499 only:  Special Tool Holder C-4685 Screw C-4685-B2 Insert
C-4685-C2 Plate L-4524 Installation Thrust Washer L-4524-C4 Screw
C4685-C1

 Recall # 499 & # 521:  Engine Support Tool C-4852


Important:  Most steps of this service procedure are common for
vehicles in notifications # 499 and # 521. Those additional steps
required for # 499 are labeled "For vehicles in notification # 499
only".


1. With the ignition in the OFF position, disconnect the battery.

2. Remove the PCV tube and upper timing belt cover screws (Figure 1)
and remove the cover.


3. Raise the vehicle on a hoist. Drain the engine oil.

4. Remove the right front tire and wheel assembly.

5. Remove the right inner splash shield to expose the accessory drive
belt (Figure 2).

6. Relieve tension and remove the accessory drive belt (Figure 3).

7. Remove 5 screws fastening the crankshaft accessory pulley, remove
crankshaft pulley, water pump pulley and drive belt tensioner (Figure
3).

8.Remove only the bottom two lower timing belt cover screws to allow
the cover to be moved away for access to the timing belt (Figure 4).

9. Remove the accessory drive belt idler pulley bracket (Figure 5).

10. Loosen the timing belt tensioner and remove the timing belt idler
pulley (Figure 5). Remove the belt from the camshaft pulley,
intermediate shaft pulley and crank shaft sprocket.  NOTE:  Figure 5 is
shown with the lower belt cover removed for illustration purposes.

11. For vehicles in notification # 499 only: Replace the crankshaft
timing sprocket as follows:
 (A) Remove the crankshaft sprocket using Special Tool Holder C-4685,
 Screw C-4685-B2 and Insert C-4685-C2, (Figure 6).  Note:  Do not use
an impact wrench on the special tool.

 (B) Install the supplied sprocket using Plate L-4524, Installation
 Thrust Washer L-4524-C4 and Screw C-4685-C1, (Figure 6). Refasten with
 the original bolt and tighten to 85 ft.lbs. (115 N-m) torque.

12. Lower the vehicle.

13. (All vehicles): Remove the air cleaner fresh air duct.

14. Remove the ignition cable cover (Figure 7).

15. Remove the rocker cover and loosen each rocker arm assembly
fastener 3 turns (Figure 8).

16. Align and pin both intake and exhaust cam sprockets with 3/16"
drills, # 13 or # 14 drills or pin punches (Figure 9) to holes in the
cylinder heads.

17. Remove the spark plugs.

18. Install a dial indicator in the number 1 spark plug hole (Figure
10).


19. Rotate the crankshaft until the number 1 piston is at top dead
center (TDC). Mark the engine block opposite the TDC mark on the
crankshaft timing sprocket, for TDC reference (Figure 10).

20. Locate the piece of foam rubber (Stuffer or Stone Guard) that is
pushed into the right engine mount bracket (Figure 11). Push out the
existing foam rubber piece and install the supplied, new piece. (The
new piece should be positioned so that the bottom of the rubber is
approximately 1-1/4" from the lower edge of the mount bracket).

21. Support the engine with Engine Support Tool C-4852. Separate the
right front engine mount bracket.

22. Raise the vehicle.

23. Remove the driveshaft support bracket.


24. Remove the transmission inspection cover.

25. Remove the shield at the K-frame, above the power steering tubes.

26. Remove the oil pan.

27. Remove the oil pump pickup tube.

28. Remove the oil pump.

29. Remove the oil pump intermediate shaft pulley (Figure 12).

30. Remove the intermediate shaft retainer.

31. Remove the intermediate shaft.

32.Transfer the key from the removed intermediate shaft to the supplied
shaft and install the supplied intermediate shaft.

33. Apply form-in-place gasket material to the intermediate shaft
retainer contact surface, reinstall the retainer and tighten the bolts
to 105 in.lbs. (12 N-m) torque.

34. Reinstall the intermediate shaft pulley and tighten the bolt to 53
ft.lbs. (72 N-m) torque.

35. Apply sealer (Loctite 515 or equivalent) to the supplied oil pump
body-to-block interface (machined surface). Install the oil pump.
Tighten the 2 bolts to 200 in. lbs. (23 N-m) torque.

CAUTION:  The oil pump must be held securely in place during the pump
screw installation and tightening process.

36. Install the oil pump pickup tube and tighten 2 bolts to 250 in.lbs.
(28 N-m) torque.


37. Reinstall the oil pan using the supplied gaskets. (Hold the gaskets
in place with RTV for ease of assembly). Tighten M6 bolts to 220
in.lbs. (25 N-m) and M8 bolts to 260 in.lbs. (29 N-m) torque.

38. Remove and discard the engine oil filter. Install a new Mopar
filter.

39. Locate the turbocharger oil return tube at the base of the
turbocharger (Figure 13).

40. Disconnect the tube from the turbocharger.

41. Loosen the return hose clamp at the drainback nipple on the engine
block and remove the tube and hose assembly.

42. Remove the return hose from the tube and attach the supplied hose.

43. Slide the supplied protective sleeve over the supplied hose and
install the tube and hose assembly.

44. Reinstall the following parts:  - Shield at K-frame - Transmission
inspection cover - Driveshaft support bracket.1w


45. Lower the vehicle.

IMPORTANT:  Correct tensioning of the timing belt is critical to engine
performance and durability. Failure to follow the procedure specified
below will result in premature timing belt wear and possible engine
damage.

46. With the camshafts pinned and the crankshaft at TDC, install the
timing belt and idler pulley as shown in Figure 14 (note direction to
install belt).

47. With the camshaft pins still installed, install a belt tension
gauge on the timing belt (Figure 15).

Note:  The belt tension gauge must be installed between the belt teeth
to get an accurate reading.

Rotate the tensioner to adjust the belt tension to 70 pounds (311 N)
for used belts. If installing a new belt, the tension adjustment should
be 110 pounds (489 N).


48. Remove both camshaft pins, rotate the crankshaft clockwise 2 full
revolutions (back to the TDC mark) and check the alignment of both
camshaft sprockets to the cylinder head index holes by reinserting both
pins. Do not reverse rotate the crankshaft or attempt to rotate the
crankshaft using the cam or accessory shaft attaching screw.


CAUTION:  Do not allow oil or solvents to contact the timing belt as
they can deteriorate the rubber and cause tooth skipping.


49. Recheck the belt tension and repeat steps 47 and 48 as necessary to
obtain proper belt tension. Be certain to recheck the camshaft sprocket
alignment with each re-adjustment. When proper tension has been
obtained remove the camshaft pins and proceed to step 50.

50. Reinstall the accessory belt idler pulley bracket and tighten the
bolts to 40 ft.lbs. (54 N-m) torque.

51. Tighten the rocker arm shafts to 210 in.lbs.(24 N-m) torque in the
sequence shown in Figure 16.


52. Install the rocker cover and tighten the bolts to 115 in.lbs. (13
N-m) torque. Install the spark plugs and tighten them to 220 in.lbs (25
N-m) torque. Install the ignition cables and ignition cable cover.

53. For vehicles in notification # 499 only: Replace the PCV vacuum
hose with the supplied hose (Figure 17).

54. (All vehicles): Reposition the lower timing belt cover and install
the 2 lower screws. Tighten them to 105 in.lbs. (12 N-m) torque.

55. Install the upper timing belt cover and tighten the screws to 105
in.lbs.(12 N-m) torque.

56. Reinstall the right front engine mount (Fiqure 18) usinq the torque
values shown in the figure.

57. Install the PCV tube.

58. Install the air cleaner. Install the air cleaner hose clamp with
the screw on the top of the hose, so that it does not interfere with
the heat shield, (Figure 19). Tighten the clamp to 30 in.lbs. (4 N-m)
torque.

NOTE:  When installing the air cleaner, ensure that the oxygen sensor
wiring is routed and clipped between the heat shield and the air
cleaner, above the heat shield. Check that the oxygen sensor wiring
connector is oriented properly (Figure 20) and clipped to the heat
shield to prevent the harness from contacting the turbocharger housing
or exhaust manifold. Use the supplied clips to secure the wiring and
the wiring connector in the event that either is broken.

CAUTION:  The oxygen sensor wiring must be routed above the heat shield
and secured to prevent heat damage to the harness.

59. Ensure that the routing of the wiring at the right side shock tower
is correct. The clip should be in the upper hole (Figure 21). If only
one hole is present at the right side shock tower, drill a 1/4 inch
hole 1 inch above the existing hole and insert the wiring clip in the
upper hole.

60. Raise the vehicle.

61.Install the crankshaft pulley and tighten the bolts to 280 in.lbs
(31 N-m) torque, (Figure 22).


For vehicles in notification # 499 only: Use the 5 new bolts from the
parts package. (A damaged crankshaft timing sprocket could have damaged
the original bolts. The new, 5 mm longer bolts are required for this
application.)


62. Install the water pump pulley and tighten the bolts to 250 in.lbs
(28 N-m) torque, (Figure 22).

63. Install the idler pulley. Tighten the bolts to 40 ft.lbs (54 N-m)
torque, (Figure 22).

64. Install the accessory drive belt tensioner pulley. Start the bolt,
finger tighten it and then tighten it to 40 ft.lbs.(54 N-m) torque.

65. Install the accessory drive belt. (Figure 22).

NOTE:  The drive belt is provided with a dynamic tensioner to maintain
proper belt tension. No additional adjustment is required.

66. Install the right inner splash shield. Tighten 3 bolts to 24
in.lbs. (3 N-m) torque.

67. Install the right front tire and wheel assembly.

68. Lower the vehicle.

69. Fill with new engine oil to the proper level.

70. Reconnect the battery ground.

71. Start the engine and check for leaks.

Go back to the Spirit R/T FAQ!