Jeep XJ. Manual — part 308
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) Install the serpentine drive belt. (refer to
Group 7, Cooling System for the proper procedure).
(17) Install the air cleaner and ducting.
(18) Connect the hoses to the engine thermostat
housing and fill the cooling system to the specified
level (refer to Group 7, Cooling Systems for the
proper procedure).
(19) The automatic transmission throttle linkage
and cable must be adjusted after completing the
engine cylinder head installation (refer to Group 21,
Transmissions for the proper procedures).
(20) Install the temperature sending unit and con-
nect the wire connector.
(21) If equipped with air conditioning, install A/C
compressor and charge A/C system (refer to Group 24
Heating and Air Conditioning).
(22) Connect negative cable to battery.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the engine thermostat opens. Add coolant, if
required.
VALVES AND VALVE SPRINGS
This procedure is done with the engine cylinder
head removed from the block.
REMOVAL
(1) Remove the engine cylinder head from the cyl-
inder block.
(2) Use
Valve
Spring
Compressor
Tool
MD-998772A and compress each valve spring.
(3) Remove the valve locks, retainers, springs and
valve stem oil seals. Discard the oil seals.
(4) Use a smooth stone or a jewelers file to remove
any burrs on the top of the valve stem, especially
around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
INSTALLATION
(1) Thoroughly clean the valve stems and the valve
guide bores.
(2) Lightly lubricate the stem.
(3) Install the valve in the original valve guide
bore.
(4) Install the replacement valve stem oil seals on
the valve stems. If the 0.381 mm (0.015 inch) over-
size valve stems are used, oversize oil seals are
required.
(5) Position the valve spring and retainer on the
engine cylinder head and compress the valve spring
with Valve Spring Compressor Tool MD-998772A.
(6) Install the valve locks and release the tool.
(7) Tap the valve spring from side to side with a
hammer to ensure that the spring is properly seated
at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks.
(8) Install the engine cylinder head.
HYDRAULIC TAPPETS
Retain all the components in the same order as
removed.
REMOVAL
(1) Remove the engine cylinder head (Refer to cyl-
inder head r&i in this section).
(2) Remove the push rods.
(3) Remove the tappets through the push rod open-
ings in the cylinder block with a Hydraulic Valve
Tappet Removal/Installation Tool (Fig. 57).
INSTALLATION
It is not necessary to charge the tappets with
engine oil. They will charge themselves within a very
short period of engine operation.
(1) Dip each tappet in Mopar Engine Oil Supple-
ment, or equivalent.
(2) Use Hydraulic Valve Tappet Removal/Installa-
tion Tool to install each tappet in the same bore from
where it was originally removed.
(3) Install the cylinder head assy (Refer to cylinder
head r&i in this section).
(4) Install the push rods in their original locations.
Fig. 57 Hydraulic Valve Tappet Removal—
Installation Tool
1 – HYDRAULIC TAPPET REMOVAL TOOL
2 – CYLINDER BLOCK
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4.0L ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)
(5) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(6) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 N·m (21 ft. lbs.) torque.
(7) Pour the remaining Mopar Engine Oil Supple-
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
least 1 609 km (1,000 miles). The oil supplement
need not be drained until the next scheduled oil
change.
(8) Install the engine cylinder head cover.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt and fan
shroud. Refer to Group 7, Cooling Systems for the
procedures.
(3) Remove the vibration damper retaining bolt
and washer.
(4) Use Vibration Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fig. 58).
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in position, align the keyway on the
vibration damper hub with the crankshaft key and
tap the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and
washer.
(3) Tighten the damper retaining bolt to 108 N·m
(80 ft. lbs.) torque.
(4) Install the serpentine drive belt. (Refer to
Group 7, Cooling Systems for the proper specifica-
tions and procedures).
(5) Connect negative cable to battery.
TIMING CASE COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper.
(3) Remove the fan and hub assembly and remove
the fan shroud.
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and
generator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 59).
INSTALLATION
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward
the inside of the cover. Support the cover at the seal
area while installing the seal. Force it into position
with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
Fig. 58 Vibration Damper Removal Tool 7697
1 – VIBRATION DAMPER REMOVAL TOOL
2 – WRENCH
Fig. 59 Timing Case Cover Components
1 – TIMING CASE COVER
2 – OIL SLINGER
3 – CRANKSHAFT OIL SEAL
4 – VIBRATION DAMPER PULLEY
XJ
4.0L ENGINE
9 - 101
REMOVAL AND INSTALLATION (Continued)
(3) Position the timing case cover on the oil pan
gasket and the cylinder block.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 60).
(5) Install the timing case cover-to-cylinder block
and the oil pan-to-timing case cover bolts.
(6) Tighten the 1/4 inch cover-to-block bolts to 7
N·m (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 N·m (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 9.5 N·m
(84 in. lbs.) torque.
(7) Remove the cover alignment tool.
(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 N·m (80 ft. lbs.)
torque.
(10) Install the A/C compressor (if equipped) and
generator bracket assembly.
(11) Install the engine fan and hub assembly and
shroud.
(12) Install the serpentine drive belt.
(13) Connect negative cable to battery.
TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud.
(3) Remove the serpentine drive belt.
(4) Remove the crankshaft vibration damper.
(5) Remove the timing case cover.
(6) Rotate crankshaft until the “0” timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 61).
(7) Remove the oil slinger from the crankshaft.
(8) Remove the camshaft sprocket bolt and washer
(Fig. 62).
(9) Remove
the
crankshaft
sprocket,
camshaft
sprocket and timing chain as an assembly.
Fig. 60 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 – TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
Fig. 61 Crankshaft—Camshaft Alignment
1 – CAMSHAFT SPROCKET
2 – TIMING MARKS
3 – CRANKSHAFT SPROCKET
Fig. 62 Camshaft Sprocket and Thrust Plate
1 – CAMSHAFT
2 – CAMSHAFT SPROCKET W/INTEGRAL KEY
3 – BOLT & CUP WASHER
4 – THRUST PLATE
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4.0L ENGINE
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REMOVAL AND INSTALLATION (Continued)
(10) Installation of the timing chain with the tim-
ing marks on the crankshaft and camshaft sprockets
properly aligned ensures correct valve timing. A worn
or stretched timing chain will adversely affect valve
timing. If the timing chain deflects more than 12.7
mm (1/2 inch) replace it.
INSTALLATION
Assemble the timing chain, crankshaft sprocket
and
camshaft
sprocket
with
the
timing
marks
aligned (Fig. 61).
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in the keyway on the crankshaft, install
the assembly on the crankshaft and camshaft.
(2) Install the camshaft sprocket bolt and washer
(Fig. 62). Tighten the bolt to 68 N·m (50 ft. lbs.)
torque.
(3) To verify correct installation of the timing
chain, rotate the crankshaft 2 revolutions. The cam-
shaft and crankshaft sprocket timing mark should
align (Fig. 61).
(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover.
(6) Install the timing case cover and gasket.
(7) With the key installed in the crankshaft key-
way, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 N·m (80 ft. lbs.)
torque.
(8) Install the serpentine drive belt. (refer to
Group 7, Cooling System for the proper procedure).
(9) Install the fan and hub assembly. Install the
shroud.
(10) Connect negative cable to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED
ENGINE
IS
HOT
AND
PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Disconnect negative cable from battery.
(2) Drain the cooling system. DO NOT waste reus-
able coolant. If the solution is clean, drain it into a
clean container for reuse.
(3) Remove the radiator or radiator and condenser,
if equipped with A/C (refer to Group 7, Cooling Sys-
tem for the proper procedure).
(4) Remove the engine cylinder head cover.
(5) Remove the rocker arms, bridges and pivots.
(6) Remove the push rods.
(7) Remove the engine cylinder head and gasket.
(8) Remove the hydraulic valve tappets from the
engine cylinder block.
(9) Remove the vibration damper.
(10) Remove the timing case cover.
(11) Rotate the crankshaft until the crankshaft
sprocket timing mark is aligned on centerline with
the camshaft sprocket timing mark (Fig. 64).
(12) Remove the timing chain and sprockets.
(13) Remove the front bumper and/or grille, as
required.
(14) Remove the two thrust plate retaining screws,
thrust plate and camshaft (Fig. 63).
INSTALLATION
(1) Inspect the cam lobes for wear.
(2) Inspect the bearing journals for uneven wear
pattern or finish.
(3) Inspect the bearings for wear.
(4) Inspect the distributor drive gear for wear.
(5) If the camshaft appears to have been rubbing
against the thrust washer, examine the oil pressure
relief holes in the rear cam journal. The oil pressure
relief holes must be free of debris.
(6) Lubricate the camshaft with Mopar Engine Oil
Supplement, or equivalent.
(7) Carefully install the camshaft to prevent dam-
age to the camshaft bearings (Fig. 63).
(8) Position thrust plate and install retaining
screws. Tighten screws to 24 N·m (18 ft. lbs.).
(9) Install the timing chain, crankshaft sprocket
and
camshaft
sprocket
with
the
timing
marks
aligned.
(10) Install the camshaft sprocket bolt/cup washer.
Tighten the bolt to 68 N·m (50 ft. lbs.).
Fig. 63 Camshaft
1 – CAMSHAFT
2 – CRANKSHAFT
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4.0L ENGINE
9 - 103
REMOVAL AND INSTALLATION (Continued)
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