Jeep Wrangler TJ. Manual — part 428
STANDARD PROCEDURE - CAMSHAFT
END-PLAY
(1) Oil camshaft journals and install camshaft
WITHOUT cam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 18).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
REMOVAL
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL)
(2) Remove camshaft position sensor and camshaft
target magnet. (Refer to 8 - ELECTRICAL/IGNI-
TION CONTROL/CAMSHAFT POSITION SENSOR -
REMOVAL)
(3) Remove timing belt. (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL)
(4) Remove camshaft sprockets and timing belt
rear cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(5) Bearing
caps
are
identified
for
location.
Remove the outside bearing caps first (Fig. 19).
(6)
Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 20) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(7) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Clean camshaft with a suitable solvent.
INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 21). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(3) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 21) and replace cam-
Fig. 18 Camshaft End Play - Typical
Fig. 19 Camshaft Bearing Cap Identification
Fig. 20 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
TJ
ENGINE 2.4L
9 - 27
CAMSHAFT(S) (Continued)
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wear limit is 0.254 mm (0.010 in.).
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate all camshaft bearing journals, rocker
arms and camshaft lobes.
(2) Install all rocker arms in original positions, if
reused.
(3) Position camshafts on cylinder head bearing
journals. Install right and left camshaft bearing caps
No. 2 – 5 and right No. 6. Tighten M6 fasteners to 12
N·m (105 in. lbs.) in sequence shown in (Fig. 22).
(4) Apply Mopar
t Gasket Maker to No. 1 and No.
6 bearing caps (Fig. 23). Install bearing caps and
tighten M8 fasteners to 28 N·m (250 in. lbs.).
NOTE: Bearing end caps must be installed before
seals can be installed.
(5) Install
camshaft
oil
seals.
(Refer
to
9
-
ENGINE/CYLINDER
HEAD/CAMSHAFT
OIL
SEAL(S) - INSTALLATION)
(6) Install camshaft target magnet and camshaft
position sensor.
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt. (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION)
CYLINDER HEAD COVER
REMOVAL
(1) Remove
intake
manifold.
(Refer
to
9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL)
(2) Remove ignition coil and spark plug wires.
(3) Disconnect PCV and make-up air hoses from
cylinder head cover.
(4) Remove cylinder head cover bolts.
(5) Remove cylinder head cover from cylinder
head.
CLEANING
Clean cylinder head and cover mating surfaces
using a suitable solvent.
INSPECTION
Inspect cover rails for flatness.
Fig. 21 Checking Camshaft(s) for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
Fig. 22 Camshaft Bearing Cap Tightening Sequence
Fig. 23 Camshaft Bearing Cap Sealing
1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
MAKER
9 - 28
ENGINE 2.4L
TJ
CAMSHAFT(S) (Continued)
INSTALLATION
NOTE: Replace spark plug well seals and bolt
assemblies when installing a new cylinder head
cover gasket.
(1) Install new cylinder head cover gaskets and
spark plug well seals (Fig. 24).
(2) Replace cylinder head cover bolt assemblies
(Fig. 25).
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3)
Apply Mopar
t Engine RTV GEN II at the
camshaft cap corners and at the top edges of the 1/2
round seal (Fig. 26).
Fig. 24 Spark Plug Well Seals
Fig. 25 Cylinder Head Cover Bolt Assembly
Fig. 26 Sealer Locations - Typical
1 – SEALER LOCATION
TJ
ENGINE 2.4L
9 - 29
CYLINDER HEAD COVER (Continued)
(4)
Install cylinder head cover assembly to cylin-
der head. Install all bolts, ensuring the two (2) bolts
containing the sealing washer are located in the cen-
ter locations of cover. Tighten bolts in sequence
shown in (Fig. 27). Using a 3 step torque method as
follows:
(a) Tighten all bolts to 4.5 N·m (40 in. lbs.).
(b) Tighten all bolts to 9.0 N·m (80 in. lbs.).
(c) Tighten all bolts to 12 N·m (105 in. lbs.).
(5) Install intake manifold.
(6) Install ignition coil and spark plug wires.
Tighten fasteners to 12 N·m (105 in. lbs.).
(7) If the PCV valve was removed, apply Mopar
t
Thread Sealant with Teflon to threads and install
valve to cylinder head cover. Tighten PCV valve to 8
N·m (70 in. lbs.).
(8) Connect PCV and make-up air hoses to cylin-
der head cover.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The four valves per cylinder are opened by using
roller rocker arms which pivot on hydraulic lash adjust-
ers. The valves have chrome plated valve stems. Viton
rubber valve stem seals are integral with the spring
seats. They have chrome plated stems to prevent scuff-
ing. Viton rubber valve stem seals are integral with the
spring seats. The valves, spring retainers,and locks, are
the 3 - bead lock design
CLEANING
(1) Clean
all
valves
thoroughly
and
discard
burned, warped and cracked valves.
VALVE SPRINGS
REMOVAL
REMOVAL - CYLINDER HEAD ON
(1) Remove camshafts.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772-A with adapter
6779 (Fig. 28), compress valve springs and remove
valve locks.
(5) Remove valve spring(s).
(6) Remove valve stem seal(s) by a using valve
stem seal tool (Fig. 30).
REMOVAL - CYLINDER HEAD OFF
(1) With cylinder head removed from cylinder
block, compress valve springs using a universal valve
spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. Identify valves, locks and
retainers to insure installation in original location.
(4) Inspect the valves. (Refer to 9 - ENGINE/CYL-
INDER HEAD/VALVE SPRINGS - INSPECTION)
Fig. 27 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 28 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSE
9 - 30
ENGINE 2.4L
TJ
CYLINDER HEAD COVER (Continued)
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