Timing Chain Tensioner

This procedure covers removal and replacement of the timing chain tensioner on the 1992 Dodge Viper 8.0L V10 engine, requiring partial front accessory removal and timing cover access panel work.

Warnings

Tools required

Parts

• Timing chain tensioner assembly × 1 — Use OEM Mopar specification
• Tensioner cap crush washer × 1 — Use OEM specification
• Timing cover gasket or RTV sealant × 1 — Mopar RTV or equivalent high-temp silicone
• Engine oil and filter × 1 — Standard service items

Fluids

• 10W-30 conventional engine oil — 11 qt

Preparation

1. Ensure engine is completely cold to touch
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on jack stands and ensure secure support on frame rails
4. Remove engine cover/beauty cover if equipped
5. Place oil drain pan under engine and drain engine oil completely by removing drain plug
6. Remove oil filter to ensure complete drainage
7. Document or photograph serpentine belt routing before removal

Procedure

1. 1

   Remove serpentine drive belt
   Locate the serpentine belt tensioner on the front of the engine. Using a serpentine belt tool or breaker bar, rotate the tensioner to relieve tension (verify direction against the service manual, as the mechanism may be an adjuster/jackscrew rather than a spring tensioner) and slide the belt off the pulleys. Release tensioner slowly and remove belt from engine bay.
2. 2

   Remove front accessory components for access
   Remove the power steering pump mounting bolts (verify exact count and locations against the service manual) and secure the pump aside with wire or bungee cord without disconnecting hydraulic lines. Remove the alternator mounting bolts and position alternator aside similarly. These components obstruct access to the timing cover area and must be moved without disconnecting lines or wiring.
3. 3

   Remove harmonic balancer/crankshaft pulley
   Remove the center crankshaft bolt using a breaker bar (may require impact wrench due to high torque). Once center bolt is removed, use a harmonic balancer puller to extract the balancer from the crankshaft. Do not pry against the balancer or use a jaw puller that grips the outer ring only. Note the crankshaft position marking before removal for reference.
4. 4

   Remove timing cover access bolts
   Locate and remove the timing cover perimeter bolts (verify exact count and locations against the factory service manual). These bolts secure the outer timing cover to the engine block. Clean the area around the cover to prevent debris from entering the timing chamber.
   Torque spec

   Timing Cover Access Bolts12 Nm (9 lb-ft)
5. 5

   Remove timing cover section
   Carefully pry the timing cover away from the engine block using a plastic trim tool or gasket scraper at the designated pry points (typically cast into the cover). Work around the perimeter evenly to break the gasket seal. Once loose, pull the cover forward and away to expose the timing chain, gears, and tensioner assembly. Inspect the gasket surface and timing chain condition.
6. 6

   Verify engine timing position
   Before removing the tensioner, confirm the crankshaft is at TDC (top dead center) for cylinder #1 or note the current timing marks. The camshaft sprocket timing mark should align with its reference mark on the crankshaft sprocket per the factory timing diagram (this is a single in-block camshaft OHV engine). Record or photograph the current chain position for reference during reassembly. Do not rotate the engine from this point forward until the new tensioner is installed.
7. 7

   Remove timing chain tensioner cap
   Locate the tensioner cap/plug on the engine block (typically on the passenger side of the timing cover area). Using the appropriate socket, carefully loosen and remove the tensioner cap. Be prepared for residual oil drainage from this area. Remove and discard the old crush washer from the cap.
   Torque spec

   Tensioner Cap/Plug30 Nm (22 lb-ft)
8. 8

   Remove tensioner housing bolts
   Locate the 2 tensioner housing mounting bolts that secure the tensioner body to the engine block. Remove these bolts in a cross-pattern sequence to evenly release tension. Keep track of bolt locations as they may be different lengths.
   Torque spec

   Tensioner Housing Bolts25 Nm (18 lb-ft)
9. 9

   Extract timing chain tensioner assembly
   With mounting bolts removed, carefully grasp the tensioner body and pull it straight out from the engine block. The tensioner is spring-loaded and may have residual tension. Control the removal to prevent sudden movement. Inspect the old tensioner for wear, scoring, or hydraulic fluid leakage. Inspect the tensioner bore in the engine block for debris or damage.
10. 10

    Prepare new tensioner assembly
    Remove the new tensioner from packaging and inspect for shipping damage. If the tensioner is hydraulic type, verify it is properly primed per manufacturer instructions (may require manual compression and release cycles). Some tensioners come with a retaining pin installed to keep them compressed during installation—do not remove this pin yet. Clean the tensioner mounting surface on the engine block with a lint-free cloth.
11. 11

    Install new timing chain tensioner
    Apply a light coat of clean engine oil to the tensioner body O-rings or seals. Carefully insert the new tensioner assembly into the engine block bore, ensuring proper alignment with the mounting holes. Push firmly until the tensioner is fully seated against the block mounting surface. Hand-start both tensioner housing mounting bolts.
    Torque spec

    Tensioner Housing Bolts25 Nm (18 lb-ft)
12. 12

    Torque tensioner housing bolts in sequence
    Tighten the tensioner housing bolts in a cross-pattern sequence to the factory-specified torque (verify exact value in the service manual). This ensures even loading and proper sealing. Verify both bolts are fully torqued and that the tensioner body is flush against the engine block mounting surface.
    Torque spec

    Tensioner Housing Bolts25 Nm (18 lb-ft)
13. 13

    Install tensioner cap with new crush washer
    Place a new crush washer onto the tensioner cap. Thread the cap into the engine block by hand until it contacts the washer, then torque to the factory-specified value (verify exact torque in the service manual). Verify there is no oil seepage from the cap after installation.
    Torque spec

    Tensioner Cap/Plug30 Nm (22 lb-ft)
14. 14

    Release tensioner and verify chain tension
    If the new tensioner was equipped with a retaining pin, carefully remove the pin now to allow the tensioner to engage the timing chain. The tensioner should extend smoothly and apply pressure to the chain guide. Manually check the timing chain for proper tension by pressing on the chain between the cam and crank gears—there should be minimal slack (approximately 1/4 to 1/2 inch deflection maximum). Verify all timing marks remain properly aligned.
15. 15

    Reinstall timing cover
    Clean all gasket material from the timing cover and engine block mating surfaces using a gasket scraper. Apply RTV sealant in a continuous 2-3mm bead around the timing cover gasket surface, or install a new pre-cut gasket per manufacturer design. Position the timing cover onto the engine block, ensuring alignment with dowel pins if present. Install all timing cover bolts and torque to the factory-specified value in a star pattern working from center outward (verify exact bolt count and torque in the service manual).
    Torque spec

    Timing Cover Access Bolts12 Nm (9 lb-ft)
16. 16

    Reinstall harmonic balancer and crankshaft pulley
    Clean the crankshaft snout and harmonic balancer hub. Apply a small amount of clean engine oil to the crankshaft snout. Slide the harmonic balancer onto the crankshaft, aligning the keyway. Install the center crankshaft bolt and torque to the factory-specified value (verify exact torque with the service manual, as it is likely significantly higher than a typical small-engine spec). Ensure the balancer is fully seated and timing reference marks are visible.
17. 17

    Reinstall accessories and serpentine belt
    Reinstall the alternator and power steering pump to their original positions using the mounting bolts. Torque mounting bolts to specification. Route the serpentine belt according to the documented routing pattern, using the tensioner to load the belt onto all pulleys. Verify the belt is properly seated in all pulley grooves.
18. 18

    Refill engine oil and reconnect battery
    Install a new oil filter and torque to specification. Reinstall the oil drain plug with a new crush washer if applicable. Fill the engine with the factory-specified quantity and viscosity of engine oil (verify exact capacity and grade in the owner's manual/service manual). Reinstall the engine cover. Reconnect the negative battery cable. Lower the vehicle from jack stands.

Reassembly

1. All reassembly steps are integrated into the procedure steps above
2. Ensure all electrical connectors and ground straps are properly reconnected
3. Double-check all fasteners are torqued to specification before starting engine
4. Allow RTV sealant on timing cover to cure per manufacturer recommendation (typically 1 hour) before starting engine if RTV was used

Verification

• Start the engine and verify immediate oil pressure indication on the gauge
• Listen for abnormal timing chain noise or rattling during startup—chain should be quiet with proper tensioner function
• Inspect the timing cover, tensioner cap, and oil pan for any signs of oil leaks while engine is running
• Allow engine to reach normal operating temperature and verify no leaks develop
• Rev engine to 2000-2500 RPM briefly and listen for timing chain noise—should remain quiet throughout RPM range
• Shut down engine, wait 10 minutes, and recheck oil level. Top off if necessary
• Perform a test drive and verify normal engine operation with no unusual noises or vibrations

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