Jeep XJ. Manual — part 294
(10) With the key inserted in the keyway in the
crankshaft, install the vibration damper, washer and
bolt. Lubricate and tighten the bolt to 108 N·m (80 ft.
lbs.) torque.
(11) Install the fan and shroud.
(12) 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.
(4) Scribe a mark on the distributor housing in
line with the lip of the rotor.
(5) Scribe a mark on the distributor housing near
the clamp and continue the scribe mark on the cylin-
der block in line with the distributor mark.
(6) For ease of installation, note the position of the
rotor and distributor housing in relation to adjacent
engine components.
(7) Remove the distributor and ignition wires.
(8) Remove the engine cylinder head cover.
(9) Remove the rocker arms, bridges and pivots.
(10) Remove the push rods.
(11) Remove the hydraulic valve tappets from the
engine cylinder head.
(12) Remove the vibration damper.
(13) Remove the timing case cover.
(14) Remove the timing chain and sprockets.
(15) Remove the camshaft (Fig. 69).
INSTALLATION
(1) Inspect the cam lobes for wear.
Fig. 67 Loading Timing Chain Tensioner
1 – LOCK
2 – UNLOCK
3 – TENSIONER BLOCK
4 – TENSIONER LEVER
Fig. 68 Verify Sprocket—Chain Installation
1 – CAMSHAFT SPROCKET
2 – 20 PINS
3 – CRANKSHAFT SPROCKET
4 – TIMING MARKS
Fig. 69 Camshaft
1 – CAMSHAFT
2 – CRANKSHAFT
9 - 44
2.5L ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)
(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 timing case cover, examine the oil pres-
sure 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. 69).
(8) Turn the tensioner lever to the unlocked (down)
position (Fig. 70).
(9) Pull the tensioner block toward the tensioner
lever to compress the spring. Hold the block and turn
the tensioner lever to the lock position (Fig. 70).
(10) Install the timing chain, crankshaft sprocket
and
camshaft
sprocket
with
the
timing
marks
aligned.
(11) Install the camshaft sprocket retaining bolt
and washer. Tighten the bolt to 108 N·m (80 ft. lbs.)
torque.
(12) Release the timing chain tensioner by moving
the lever to the unlock position (Fig. 70).
(13) Install the timing case cover with a replace-
ment oil seal (Fig. 71). Refer to Timing Case Cover
Installation.
(14) Install the vibration damper.
(15) Install the hydraulic valve tappets.
(16) Install the push rods.
(17) Install the rocker arms, bridges and pivots.
(18) Install the engine cylinder head cover.
(19) Position the oil pump gear. Refer to Distribu-
tor in the Component Removal/Installation section of
Group 8D, Ignition Systems.
(20) Install the distributor and ignition wires.
Refer to Distributor in the Component Removal/In-
stallation section of Group 8D, Ignition Systems.
(21) Install the radiator or radiator and condenser,
if equipped with A/C.
(22) Fill the cooling system.
(23) Connect negative cable to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO
NOT
LOOSEN
THE
RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain the radiator. DO NOT waste reusable
coolant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
(4) Disconnect the radiator overflow tube, radiator
hoses, automatic transmission fluid cooler pipes (if
equipped).
(5) Remove the radiator.
(6) If equipped with air conditioning:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
Fig. 70 Loading Timing Chain Tensioner
1 – LOCK
2 – UNLOCK
3 – TENSIONER BLOCK
4 – TENSIONER LEVER
Fig. 71 Timing Case Cover
1 – TIMING CASE COVER
2 – CAMSHAFT
3 – CRANKSHAFT
XJ
2.5L ENGINE
9 - 45
REMOVAL AND INSTALLATION (Continued)
(a) Remove the A/C compressor serpentine drive
belt idler pulley.
(b) Disconnect and remove the generator.
(c) Remove the A/C condenser attaching bolts
and move the condenser and receiver/drier assem-
bly up and out of the way.
(7) Remove the serpentine drive belt.
(8) Remove the crankshaft vibration damper.
(9) Remove the timing case cover. Clean the gasket
material from the cover.
(10) Rotate
crankshaft
until
the
crankshaft
sprocket timing mark is closest to and on the center
line with the camshaft sprocket timing mark (Fig.
72).
(11) Remove camshaft sprocket retaining bolt.
(12) Remove the crankshaft oil slinger.
(13) Remove the sprockets and chain as an assem-
bly (Fig. 73).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) Inspect the damaged camshaft pin.
(15) If the pin is a spring-type pin, remove the bro-
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.
(16) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(17) Drill into the pin center with a 4 mm (5/32
inch) drill bit.
(18) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install
the
camshaft
sprocket,
crankshaft
sprocket and timing chain with the timing marks
aligned (Fig. 72).
(5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
sprocket timing mark as shown in (Fig. 74). Count
the number of chain pins between the timing marks
of both sprockets. There must be 20 pins.
(6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket bolt to 108 N·m
(80 ft. lbs.) torque.
(8) Check the valve timing.
(9) Coat both sides of the replacement timing case
cover gasket with gasket sealer. Apply a 3 mm (1/8
inch) bead of Mopar Silicone Rubber Adhesive Seal-
ant, or equivalent to the joint formed at the timing
case cover and cylinder block.
(10) Position the timing case cover on the oil pan
gasket and the cylinder block.
(11) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening of
the cover (Fig. 75).
(12) Install the timing case cover-to-cylinder block
bolts. Install the oil pan-to-timing case cover bolts.
(13) 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 14 N·m
Fig. 72 Timing Chain Alignment
1 – TIMING MARKS
Fig. 73 Camshaft and Crankshaft Sprocket and
Chain
1 – CAMSHAFT SPROCKET
2 – CRANKSHAFT SPROCKET
3 – CHAIN
9 - 46
2.5L ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)
(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 N·m (156 in. lbs.) torque.
(14) Remove the cover alignment tool and install a
replacement oil seal into the cover.
(15) Install the vibration damper on the crank-
shaft.
(16) Lubricate and tighten the damper bolt to 108
N·m (80 ft. lbs.) torque.
(17) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive
belt idler pulley.
(b) Install the generator.
(c) Install the A/C condenser and receiver/drier
assembly.
(18) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(19) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(20) Install the fan and shroud.
(21) Connect negative cable to battery.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled,
babbitt-lined bearings that are pressed into the cyl-
inder block and then line reamed. The camshaft
bearing bores and bearing diameters are not the
same size. They are stepped down in 0.254 mm
(0.010 inch) increments from the front bearing (larg-
est) to the rear bearing (smallest). This permits eas-
ier removal and installation of the camshaft. The
camshaft bearings are pressure lubricated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recom-
mended tool 8544 Camshaft Bushing Remover
Installer.
Camshaft end play is maintained by the load
placed on the camshaft by the oil pump and distrib-
utor drive gear. The helical cut of the gear holds the
camshaft sprocket thrust face against the cylinder
block face.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the spark plugs.
(3) Raise the vehicle.
(4) Remove the oil pan and oil pump.
(5) Remove only one main bearing cap and lower
insert at a time (Fig. 76).
(6) Remove the lower insert from the bearing cap.
(7) Remove the upper insert by LOOSENING (DO
NOT REMOVE) all of the other bearing caps. Now
insert a small cotter pin tool in the crankshaft jour-
nal oil hole. Bend the cotter pin as illustrated to fab-
ricate the tool (Fig. 77). With the cotter pin tool in
place, rotate the crankshaft so that the upper bear-
ing insert will rotate in the direction of its locking
tab. Because there is no hole in the No.3 main jour-
nal, use a tongue depressor or similar soft-faced tool
Fig. 74 Verify Crankshaft—Camshaft Installation
1 – CAMSHAFT SPROCKET
2 – 20 PINS
3 – CRANKSHAFT SPROCKET
4 – TIMING MARKS
Fig. 75 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 – TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
XJ
2.5L ENGINE
9 - 47
REMOVAL AND INSTALLATION (Continued)
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