Jeep Cherokee (XJ): Timing case cover. Timing chain and sprockets. Camshaft

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 2.5L engine > Removal and installation > Timing case cover. Timing chain and sprockets. Camshaft

Timing case cover

REMOVAL

(1) Disconnect battery negative cable.

(2) Remove accessory drive belt (Refer to Group 07, Cooling System for proper procedure) (3) Remove the accessory drive brackets that are attached to the timing case cover.

(4) Remove the fan and hub assembly and remove the fan shroud.

(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 vibration damper (Fig. 63).

(7) Remove the oil pan-to-timing case cover bolts and timing case cover-to-cylinder block bolts.

(8) Remove the timing case cover and gasket from the engine.

(9) Pry the crankshaft oil seal from the front of the timing case cover (Fig. 63).

Fig. 63 Timing Case Cover Components
Fig. 63 Timing Case Cover Components

1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY

INSTALLATION

(1) Clean the timing case cover, oil pan and cylinder block gasket surfaces.

(2) 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.

(3) Position the gasket on the cylinder block.

(4) Position the timing case cover on the oil pan gasket and the cylinder block.

(5) Insert Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening in the cover (Fig. 64).

Fig. 64 Timing Case Cover Alignment and Seal Installation Tool 6139
Fig. 64 Timing Case Cover Alignment and Seal Installation Tool 6139

1 - TIMING CASE COVER ALIGNMENT AND SEAL INSTALLATION TOOL

(6) Install the timing case cover-to-cylinder block and the oil pan-to-timing case cover bolts.

(7) 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 bolts to 9.5 N·m (84 in.

lbs.) torque.

(8) Remove the cover alignment tool.

(9) Apply a light film of engine oil on the vibration damper hub contact surface of the seal.

(10) 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 crankshaft, install the vibration damper, washer and bolt. Lubricate and tighten the bolt to 108 N·m (80 ft.

lbs.) torque.

(11) Install the A/C compressor (if equipped) and generator bracket assembly.

(12) Install the engine fan and hub assembly and shroud.

(13) Install the accessory drive belt and tighten to obtain the specified tension.

(14) Connect negative cable to battery.

Timing chain and sprockets

The chain drive system ie equipped with a timing chain tensioner which reduces noise and prolongs timing chain life. In addition, it compensates for wear and temperature changes on the valve train for proper engine operation.

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. 65).

(7) Remove the oil slinger from the crankshaft.

(8) Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly (Fig.

66).

(9) To replace the timing chain tensioner, the oil pan must be removed.

INSTALLATION

(1) Turn the tensioner lever to the unlocked (down) position (Fig. 67).

(2) 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. 67).

(3) Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key.

With the key in the crankshaft keyway, install the crankshaft, camshaft sprockets and timing chain.

Ensure the timing marks on the sprockets are properly aligned (Fig. 65).

Fig. 65 Crankshaft-Camshaft Alignment
Fig. 65 Crankshaft-Camshaft Alignment

1 - TIMING MARKS

Fig. 66 Camshaft and Crankshaft Sprockets and Chain
Fig. 66 Camshaft and Crankshaft Sprockets and Chain

1 - CAMSHAFT SPROCKET
2 - CRANKSHAFT SPROCKET
3 - CHAIN

(4) Install the camshaft sprocket retaining bolt and washer. Tighten the bolt to 108 N·m (80 ft. lbs.) torque.

(5) To verify correct installation of the timing chain, turn the crankshaft to position the camshaft sprocket timing mark as shown in (Fig. 68). Count the number of chain pins between the timing marks of both sprockets. There must be 20 pins.

(6) Turn the chain tensioner lever to the unlocked (down) position (Fig. 67).

(7) Install the oil slinger.

(8) Replace the oil seal in the timing case cover.

(9) Install the timing case cover and gasket.

Fig. 67 Loading Timing Chain Tensioner
Fig. 67 Loading Timing Chain Tensioner

1 - LOCK
2 - UNLOCK
3 - TENSIONER BLOCK
4 - TENSIONER LEVER

Fig. 68 Verify Sprocket-Chain Installation
Fig. 68 Verify Sprocket-Chain Installation

1 - CAMSHAFT SPROCKET
2 - 20 PINS
3 - CRANKSHAFT SPROCKET
4 - TIMING MARKS

(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 OPERATED 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 reusable 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 cylinder 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).

Fig. 69 Camshaft
Fig. 69 Camshaft

1 - CAMSHAFT
2 - CRANKSHAFT

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 timing case cover, 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 damage 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 replacement oil seal (Fig. 71). Refer to Timing Case Cover Installation.

(14) Install the vibration damper.

Fig. 70 Loading Timing Chain Tensioner
Fig. 70 Loading Timing Chain Tensioner

1 - LOCK
2 - UNLOCK
3 - TENSIONER BLOCK
4 - TENSIONER LEVER

(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.

Fig. 71 Timing Case Cover
Fig. 71 Timing Case Cover

1 - TIMING CASE COVER
2 - CAMSHAFT
3 - CRANKSHAFT

(19) Position the oil pump gear. Refer to Distributor 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/Installation 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.

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