Jeep Wrangler TJ. Manual — part 453
(3) Fill the oil pan with oil to the specified level.
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING
(1) Disconnect the spark plug wires and remove
the spark plugs.
(2) Remove the engine cylinder head cover .
(3) Remove the capscrews, bridge and pivot assem-
bly, and rocker arms from above the No.1 cylinder.
(4) Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
(5) Rotate the crankshaft until the No.6 piston is
at top dead center (TDC) on the compression stroke.
(6) Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90°.
(7) Install a dial indicator on the end of the No.1
cylinder intake valve push rod. Use rubber tubing to
secure the indicator stem on the push rod.
(8) Set the dial indicator pointer at zero.
(9) Rotate the crankshaft clockwise (viewed from
the front of the engine) until the dial indicator
pointer indicates 0.305 mm (0.012 inch) travel dis-
tance (lift).
(10) The timing notch index on the vibration
damper should be aligned with the TDC mark on the
timing degree scale.
(11) If the timing notch is more than 13 mm (1/2
inch) away from the TDC mark in either direction,
the valve timing is incorrect.
NOTE: If the valve timing is incorrect, the cause
may be a broken camshaft pin. It is not necessary
to replace the camshaft because of pin failure. A
spring pin is available for service replacement.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) Remove the fan, hub assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL) (if equipped) and gen-
erator 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. 87).
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.
(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. 88).
(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
t Silicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key inserted in the keyway in the
Fig. 87 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
TJ
ENGINE 4.0L
9 - 127
OIL PUMP (Continued)
crankshaft, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION) (if equipped) and
generator bracket assembly.
(11) Install the engine fan, hub assembly and
shroud (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(12) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(13) Connect negative cable to battery.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(4) Remove the crankshaft vibration damper (Refer
to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - REMOVAL).
(5) Remove the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Rotate crankshaft until the “0” timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 89).
(7) Remove the oil slinger from the crankshaft.
(8) Remove the camshaft sprocket bolt and washer
(Fig. 90).
(9) Remove
the
crankshaft
sprocket,
camshaft
sprocket and timing chain as an assembly.
(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.
Fig. 88 Timing Case Cover Alignment
1 - TIMING CASE COVER ALIGNMENT AND SEAL INSTALLATION
TOOL
Fig. 89 Crankshaft—Camshaft Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
Fig. 90 Camshaft Sprocket and Thrust Plate
1 - CAMSHAFT
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
4 - THRUST PLATE
9 - 128
ENGINE 4.0L
TJ
TIMING BELT / CHAIN COVER(S) (Continued)
INSTALLATION
Assemble the timing chain, crankshaft sprocket
and
camshaft
sprocket
with
the
timing
marks
aligned (Fig. 89).
(1) Apply Mopar
t Silicone Rubber Adhesive Seal-
ant 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. 90). 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. 89).
(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT OIL SEAL - FRONT - REMOVAL).
(6) Install the timing case cover and gasket (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT /
CHAIN COVER(S) - INSTALLATION).
(7) With the key installed in the crankshaft key-
way, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(8) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(9) Install the fan, hub assembly and shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(10) Connect negative cable to battery.
INTAKE MANIFOLD
DESCRIPTION
The intake manifold (Fig. 91) is made of cast alu-
minum and uses eleven bolts to mount to the cylin-
der head. This mounting style improves sealing and
reduces the chance of leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD
MUST
BE
REMOVED
AND
INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Disconnect the battery negative cable.
(2) Remove air cleaner inlet hose from the resona-
tor assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, vehicle speed control
cable (if equipped) and the transmission line pres-
sure cable (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC
-
AW4/THROTTLE
VALVE
CABLE - REMOVAL).
(5) Disconnect the following electrical connections
and secure their harness out of the way:
• Throttle Position Sensor
• Idle Air Control Motor
• Coolant Temperature Sensor (at thermostat
housing)
• Intake Air Temperature Sensor
• Oxygen Sensor
• Crank Position Sensor
• Six (6) Fuel Injector Connectors
• Manifold Absolute Pressure (MAP) Sensor.
(6) Disconnect HVAC, and Brake Booster vacuum
supply hoses at the intake manifold.
(7) Perform the fuel pressure release procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect and remove the fuel system supply
line from the fuel rail assembly.
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
Fig. 91 Intake Manifold 4.0L Engine
TJ
ENGINE 4.0L
9 - 129
TIMING BELT/CHAIN AND SPROCKETS (Continued)
(10) Remove the power steering pump from the
intake manifold and set aside.
(11) Raise the vehicle.
(12) Disconnect the exhaust pipes from the engine
exhaust manifolds.
(13) Lower the vehicle.
(14) Remove the intake manifold and exhaust
manifold bolts and manifolds (Fig. 92).
INSTALLATION
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement mani-
fold.
(1) Install a new engine exhaust/intake manifold
gasket over the alignment dowels on the cylinder
head.
(2) Position the engine exhaust manifolds to the
cylinder head. Install fastener Number 3 and finger
tighten at this time (Fig. 92).
(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 92).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 92).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 92).
• Fastener Numbers 1 through 5—Tighten to 33
N·m (24 ft. lbs.) torque.
• Fastener Numbers 6 and 7—Tighten to 31 N·m
(23 ft. lbs.) torque.
• Fastener Numbers 8 through 11—Tighten to 33
N·m (24 ft. lbs.) torque.
(7) Install the power steering pump to the intake
manifold.
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(9) Install the fuel system supply line to the fuel
rail assembly.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect
the
vacuum
hoses
previously
removed.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC
-
AW4/THROTTLE
VALVE
CABLE - INSTALLATION).
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the resonator assem-
bly.
(16) Raise the vehicle.
(17) Connect the exhaust pipes to the engine
exhaust manifolds. Tighten the bolts to 31 N·m (23
ft. lbs.)
(18) Lower the vehicle.
(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
Fig. 92 Intake and Exhaust Manifolds Installation
9 - 130
ENGINE 4.0L
TJ
INTAKE MANIFOLD (Continued)
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