1999-2004 JGC Engine Service Manual

WJ ENGINE 9-1
ENGINE
TABLE OF CON T EN T S
page page
ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE 4.7L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EN GI N E - 4 .0 L
TABLE OF CONTENTS
page page
ENGINE - 4.0L INTAKE/EXHAUST VALVES & SEATS

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 23
ENGINE DIAGNOSIS - INTRODUCTION. . . . . . . 3 VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICE DIAGNOSIS(PERFORMANCE) . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SERVICE (MECHANICAL) . . . . . . . . . . . . . . . . . 6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYLINDER COMPRESSION PRESSURE . . . . . . 8 ROCKER ARM / ADJUSTER ASSEMBLY
CYLINDER COMBUSTION PRESSURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 9 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FORM-IN-PLACE GASKETS AND SEALERS. . . . 9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REPAIR DAMAGED OR WORN THREADS . . . . 10 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDROSTATIC LOCK. . . . . . . . . . . . . . . . . . . . 10 VALVE STEM SEALS
CYLINDER BORE HONING. . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ENGINE CORE AND OIL GALLERY PLUGS . . . 11 VALVE SPRINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 28
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 14 VALVE SPRING TENSION TEST. . . . . . . . . . . . 28
AIR CLEANER ELEMENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ENGINE BLOCK
AIR CLEANER HOUSING CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CAMSHAFT & BEARINGS
CYLINDER HEAD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CONNECTING ROD BEARINGS
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 33
CYLINDER HEAD COVER(S) FITTING CONNECTING ROD BEARINGS . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CRANKSHAFT
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CRANKSHAFT MAIN BEARINGS
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 36
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FITTING CRANKSHAFT MAIN BEARINGS . . . . 36
9-2 ENGINE - 4.0L WJ
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 51

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ENGINE OIL LEAK . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 OIL
CRANKSHAFT OIL SEAL - FRONT STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 53
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . . . 53
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 41 OIL FILTER
CRANKSHAFT OIL SEAL - REAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 42 OIL PAN
HYDRAULIC LIFTERS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ENGINE OIL PRESSURE SENSOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 43 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PISTON & CONNECTING ROD OIL PUMP
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 44 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . 44 INTAKE MANIFOLD
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 46 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 57
PISTON RINGS INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . 57
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 47 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON RING FITTING . . . . . . . . . . . . . . . . . . 47 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
VIBRATION DAMPER EXHAUST MANIFOLD
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
STRUCTURAL SUPPORT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIMING BELT / CHAIN COVER(S)
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LUBRICATION INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIMING BELT/CHAIN AND SPROCKETS
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 51 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
EN GI N E - 4 .0 L
DESCRIPTION
Th e 4.0 Lit er (242 CID) six-cylin der en gin e is a n
In -lin e, ligh t weigh t , over h ea d va lve en gin e. Th is
en gin e is design ed for u n lea ded fu el.
Th e en gin e cylin der h ea d h a s du a l qu en ch -t ype
com bu st ion ch a m ber s t h a t cr ea t e t u r bu len ce a n d fa st
bu r n in g of t h e a ir /fu el m ixt u r e. Th is r esu lt s in bet t er
fu el econ om y.
Th e cylin der s a r e n u m ber ed 1 t h r ou gh 6 fr om fr on t
t o r ea r. Th e fir in g or der is 1-5-3-6-2-4 (F ig. 1).
Th e cr a n ksh a ft r ot a t ion is clockwise, wh en viewed
fr om t h e fr on t of t h e en gin e. Th e cr a n ksh a ft r ot a t es
wit h in seven m a in bea r in gs. Th e ca m sh a ft r ot a t es
wit h in fou r bea r in gs.
Fig. 1 Engine Firing Order

WJ ENGINE - 4.0L 9-3
EN GI N E - 4 .0 L (Cont inue d)
Th e en gin e Bu ild Da t e Code is loca t ed on a • 4t h & 5t h Digit s—Th e en gin e t ype/fu el syst em /
m a ch in ed su r fa ce on t h e r igh t side of t h e cylin der com pr ession r a t io (MX = A 4.0 Lit er (242 CID) 8.7:1
block bet ween t h e No.2 a n d No.3 cylin der s (F ig. 2). com pr ession r a t io en gin e wit h a m u lt i-poin t fu el
in ject ion syst em ).
• 6t h & 7t h Digit s—Th e da y of en gin e bu ild (01 -
31).
(1) F OR EXAMP LE: Code * 801MX12 * iden t ifies
a 4.0 Lit er (242 CID) en gin e wit h a m u lt i-poin t fu el
in ject ion syst em , 8.7:1 com pr ession r a t io a n d bu ilt on
J anuary 12, 1998.
DIAGNOSIS AND TESTING—ENGINE

DIAGNOSIS - INTRODUCTION
E n gin e dia gn osis is h elpfu l in det er m in in g t h e
ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
r ou t in e m a in t en a n ce.
Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er
m ech a n ica l (e.g., a st r a n ge n oise), or per for m a n ce
(e.g., en gin e idles r ou gh a n d st a lls).
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE ST-
ING - P r efor m a n ce) or (Refer t o 9 - E NGINE - DIAG-
NOSIS AND TE STING - Mech a n ica l). Refer t o F UE L
Fig. 2 Build Date Code Location SYSTE M for t h e fu el syst em dia gn osis.
1 - YEAR Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
2 - MONTH n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n -
3 - DAY
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
Th e digit s of t h e code iden t ify: sis is pr ovided wit h in t h e followin g:
• 1st Digit —Th e yea r (8 = 1998). • Cylin der Com pr ession P r essu r e Test
• 2n d & 3r d Digit s—Th e m on t h (01 - 12). • Cylin der Com bu st ion P r essu r e Lea ka ge Test
• Cylin der H ea d Ga sket F a ilu r e Dia gn osis
• In t a ke Ma n ifold Lea ka ge Dia gn osis
• La sh Adju st er (Ta ppet ) Noise Dia gn osis
• E n gin e Oil Lea k In spect ion
DIAGNOSIS AND TESTING - SERVICE DIAGNOSIS (PERFORMANCE)

EN GI N E PERFORM AN CE DI AGN OSI S CH ART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE), for correct
procedures. Check charging system.
(Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING), for correct procedures.
2. Corroded or loose battery 2. Clean/tighten suspect battery/

connections starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
4. Siezed accessory drive 4. Remove accessory drive belt and
component attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical 5. (Refer to 9 - ENGINE -
failure or hydro-static lock DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. (Refer to 8 -
START ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS), for correct
procedures.
2. No fuel 2. Perform fuel pressure test (Refer

to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING), and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - DIAGNOSIS
AND TESTING), for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn canshaft position sensor 2. Remove and repair camshaft
shaft position sensor.(Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
CAMSHAFT POSITION SENSOR -
REMOVAL).
3. Worn or incorrect gapped spark 3. Clean plugs and set gap. (Refer
plugs to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression. (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust 10. Install new parts as necessary
system
11. Faulty ignition coil rail 11. Test and replace, as necessary.
IGNITION CONTROL/COIL RAIL -
REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL) for
correct procedure.
2. Engine idle speed too low 2. Check Idle Air Control circuit.
3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap
plugs spark plugs. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING)
4. Faulty coil rail 4. Test and replace, if necessary.
REMOVAL)
5. Intake manifold vacuum leak 5. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
ENGINE MISSES ON 1. Worn or incorrectly gapped spark 1. Replace spark plugs or clean and
ACCELERATION plugs set gap. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING)
2. Spark plug cables defective or 2. Check Idle Air Control circuit.
crossed
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil rail 5. Test and replace as necessary.

REMOVAL)
DIAGNOSIS AND TESTING - SERVICE DIAGNOSIS (MECHANICAL)

EN GI N E M ECH AN I CAL DI AGN OSI S CH ART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats 9. Grind valves and seats
or valve faces
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
4. Excessive connecting rod Measure bearings for correct
bearing clearance clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of 5. Replace crankshaft or grind

round journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING)
4. Excessive main bearing 4. Measure bearings for correct
clearance clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of 6. Grind journals or replace
round or worn crankshaft
7. Loose flywheel or torque 7. Inspect crankshaft, flexplate/
converter flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose, 8. Inspect suction tube and clean or
broken, bent or clogged replace if necessary
9. Oil pump cover warped or 9. Install new oil pump
cracked
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket

gaskets
2. Loose fastener, broken or porous 2. Tighten, repair or replace the part
metal part
3. Front or rear crankshaft oil seal 3. Replace seal
leaking
4. Leaking oil gallery plug or cup 4. Remove and reseal threaded
plug plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION 1. CCV System malfunction 1. (Refer to 25 - EMISSIONS

OR SPARK PLUGS OIL FOULED CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new

rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in 7. Remove rings and check ring end
grooves gap and side clearance. Replace if
necessary
DIAGNOSIS AND TESTING—CYLINDER WARNING: DO NOT REMOVE THE RADIATOR CAP

WITH THE SYSTEM HOT AND UNDER PRESSURE.
COMPRESSION PRESSURE
SERIOUS BURNS FROM HOT COOLANT CAN
Th e r esu lt s of a cylin der com pr ession pr essu r e t est
OCCUR.
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c-
t ion s. Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e NOT in st a ll t h e r a dia t or ca p.
en gin e st a r t er m ot or is in good oper a t in g con dit ion . St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s n or-
Ot h er wise, t h e in dica t ed com pr ession pr essu r es m a y m a l oper a t in g t em per a t u r e, t h en t u r n OF F t h e
n ot be va lid for dia gn osis pu r poses. en gin e.
(1) Clea n t h e spa r k plu g r ecesses wit h com pr essed Rem ove t h e spa r k plu gs.
a ir. Rem ove t h e oil filler ca p.
(2) Rem ove t h e spa r k plu gs (Refer t o 8 - E LE C- Rem ove t h e a ir clea n er.
TRICAL/IGNITION CONTROL/SPARK P LUG - Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa ct u r-
RE MOVAL). er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g
(3) Secu r e t h e t h r ot t le in t h e wide-open posit ion . sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379
(4) Discon n ect t h e ign it ion coil. kP a (200 psi) m a xim u m a n d 552 kP a (80 psi) r ecom -
(5) In ser t a com pr ession pr essu r e ga u ge a n d r ot a t e m en ded.
t h e en gin e wit h t h e en gin e st a r t er m ot or for t h r ee P er for m t h e t est pr ocedu r e on ea ch cylin der a ccor d-
r evolu t ion s. in g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s. Wh ile
(6) Recor d t h e com pr ession pr essu r e on t h e t h ir d t est in g, list en for pr essu r ized a ir esca pin g t h r ou gh
r evolu t ion . Con t in u e t h e t est for t h e r em a in in g cylin - t h e t h r ot t le body, t a ilpipe or oil filler ca p open in g.
der s. Ch eck for bu bbles in t h e r a dia t or coola n t .
(Refer t o 9 - E NGINE - SP E CIF ICATIONS) for t h e All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l,
cor r ect en gin e com pr ession pr essu r es. wit h n o m or e t h a n 25% lea ka ge.
F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es-
DIAGNOSIS AND TESTING—CYLINDER su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in -
COMBUSTION PRESSURE LEAKAGE t a in ed in t h e cylin der.
Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n Refer t o CYLINDE R COMBUSTION P RE SSURE
a ccu r a t e m ea n s for det er m in in g en gin e con dit ion . LE AKAGE DIAGNOSIS CH ART below
Com bu st ion pr essu r e lea ka ge t est in g will det ect :
• E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t -
in g)
• Lea ks bet ween a dja cen t cylin der s or in t o wa t er
ja cket
• An y ca u ses for com bu st ion /com pr ession pr essu r e
loss
CY LI N DER COM BU ST I ON PRESSU RE LEAK AGE DI AGN OSI S CH ART
CONDITION POSSIBLE CAUSE CORRECTION

AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat.
THROTTLE BODY seated properly Reface or replace, as necessary
AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE seated properly Reface or replace, as necessary
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE AND Stuck or broken piston rings; Inspect for broken rings or piston.
AIR ESCAPES THROUGH OIL cracked piston; worn rings and/or Measure ring gap and cylinder
FILLER CAP OPENING ONLY cylinder wall diameter, taper and out-of-round.
Replace defective part as necessary
DIAGNOSIS AND TESTING—REAR SEAL AREA scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
LEAKS
seal.
Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e (6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
followin g st eps sh ou ld be followed t o h elp pin poin t a ssem bled. Refer t o t h e ser vice Dia gn osis—Mech a n i-
t h e sou r ce of t h e lea k. ca l, u n der t h e Oil Lea k r ow, for com pon en t s
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l in spect ion s on possible ca u ses a n d cor r ect ion s.
a r ea : (7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e
(1) Discon n ect t h e ba t t er y. cor r ect ive a ct ion h a ve been iden t ified, (Refer t o 9 -
(2) Ra ise t h e veh icle. E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g SE AL - RE AR - RE MOVAL), for pr oper r epla cem en t
cover a n d in spect r ea r of block for eviden ce of oil. pr ocedu r es.
Use a bla ck ligh t t o ch eck for t h e oil lea k:
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es STANDARD PROCEDURE—FORM-IN-PLACE
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down , GASKETS & SEALERS
possible ca u ses a r e a por ou s block, dist r ibu t or sea l, Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce
ca m sh a ft bor e cu p plu gs, oil ga lley pipe plu gs, oil ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
filt er r u n off, a n d m a in bea r in g ca p t o cylin der wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e
block m a t in g su r fa ces. obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in -
(4) If n o lea ks a r e det ect ed, pr essu r ized t h e cr a n k- p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size,
ca se a s ou t lin ed in (Refer t o 9 - E NGINE /LUBRICA- con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too
TION - DIAGNOSIS AND TE STING) t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n
r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct
CAUTION: Do not exceed 20.6 kPa (3 psi). flu id feed lin es. A con t in u ou s bea d of t h e pr oper
widt h is essen t ia l t o obt a in a lea k-fr ee ga sket .
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r !
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r !
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er.
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es MOPAR! EN GIN E RTV GEN II
t h a t ca n be polish ed ou t wit h em er y clot h . Mopa r ! E n gin e RTV GE N II is u sed t o sea l com -
pon en t s exposed t o en gin e oil. Th is m a t er ia l is a spe-
CAUTION: Use extreme caution when crankshaft cia lly design ed bla ck silicon e r u bber RTV t h a t
polishing is necessary to remove minor nicks or r et a in s a dh esion a n d sea lin g pr oper t ies wh en
9 - 10 ENGINE - 4.0L WJ
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee pr even t sm ea r in g m a t er ia l off t h e loca t ion .
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys a pplied u sin g a t h in , even coa t spr a yed com plet ely
in spect t h e pa cka ge for t h e expir a t ion da t e befor e over bot h su r fa ces t o be join ed, a n d bot h sides of a
u se. ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a
MOPAR! ATF RTV ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
Mopa r ! ATF RTV is a specifica lly design ed bla ck sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be
silicon e r u bber RTV t h a t r et a in s a dh esion a n d sea l- u sed on en gin es wit h m u lt i-la yer st eel ga sket s.
in g pr oper t ies t o sea l com pon en t s exposed t o a u t o-
m a t ic t r a n sm ission flu id, en gin e coola n t s, a n d STANDARD PROCEDURE—REPAIR DAMAGED
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce OR WORN THREADS
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect CAUTION: Be sure that the tapped holes maintain
t h e pa cka ge for t h e expir a t ion da t e befor e u se. the original center line.
MOPAR! GAS KET MAKER
Mopa r ! Ga sket Ma ker is a n a n a er obic t ype ga sket Da m a ged or wor n t h r ea ds ca n be r epa ir ed. E ssen -
m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of a ir t ia lly, t h is r epa ir con sist s of:
wh en squ eezed bet ween t wo m et a llic su r fa ces. It will • Dr illin g ou t wor n or da m a ged t h r ea ds.
n ot cu r e if left in t h e u n cover ed t u be. Th e a n a er obic • Ta ppin g t h e h ole wit h a specia l H eli-Coil Ta p, or
m a t er ia l is for u se bet ween t wo m a ch in ed su r fa ces. equ iva len t .
Do n ot u se on flexible m et a l fla n ges. • In st a llin g a n in ser t in t o t h e t a pped h ole t o br in g
MOPAR! GAS KET S EALAN T t h e h ole ba ck t o it s or igin a l t h r ea d size.
Mopa r ! Ga sket Sea la n t is a slow dr yin g, per m a -
n en t ly soft sea ler. Th is m a t er ia l is r ecom m en ded for STANDARD PROCEDURES—HYDROSTATIC
sea lin g t h r ea ded fit t in gs a n d ga sket s a ga in st lea ka ge LOCK
of oil a n d coola n t . Ca n be u sed on t h r ea ded a n d
m a ch in ed pa r t s u n der a ll t em per a t u r es. Th is m a t e- CAUTION: DO NOT use the starter motor to rotate
r ia l is u sed on en gin es wit h m u lt i-la yer st eel (MLS) the crankshaft. Severe damage could occur.
cylin der h ea d ga sket s. Th is m a t er ia l a lso will pr e-
ven t cor r osion . Mopa r ! Ga sket Sea la n t is a va ila ble in Wh en a n en gin e is su spect ed of h ydr ost a t ic lock
a 13 oz. a er osol ca n or 4oz./16 oz. ca n w/a pplica t or. (r ega r dless of wh a t ca u sed t h e pr oblem ), follow t h e
st eps below.
FORM-IN-PLACE GASKET AND SEALER (1) P er for m t h e F u el P r essu r e Relea se P r ocedu r e
APPLICATION (Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
Assem blin g pa r t s u sin g a for m -in -pla ce ga sket STANDARD P ROCE DURE ).
r equ ir es ca r e bu t it ’s ea sier t h en u sin g pr ecu t ga s- (2) Discon n ect t h e n ega t ive ca ble(s) fr om t h e ba t -
ket s. t er y.
Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied (3) In spect a ir clea n er, in du ct ion syst em , a n d
spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t in t a ke m a n ifold t o en su r e syst em is dr y a n d clea r of
t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r- for eign m a t er ia l.
r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s- (4) P la ce a sh op t owel a r ou n d t h e spa r k plu gs t o
ily be wiped off. Com pon en t s sh ou ld be t or qu ed in ca t ch a n y flu id t h a t m a y possibly be u n der pr essu r e
pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel in t h e cylin der h ea d. Rem ove t h e spa r k plu gs.
is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r- (5) Wit h a ll spa r k plu gs r em oved, r ot a t e t h e cr a n k-
in g m a t er ia l off t h e loca t ion . sh a ft u sin g a br ea ker ba r a n d socket .
Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket (6) Iden t ify t h e flu id in t h e cylin der s (coola n t , fu el,
m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d oil, et c.).
a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All (7) Be su r e a ll flu id h a s been r em oved fr om t h e
m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a cylin der s.
3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e (8) Repa ir en gin e or com pon en t s a s n ecessa r y t o
cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t pr even t t h is pr oblem fr om occu r r in g a ga in .
m a y be r em oved wit h a sh op t owel. Com pon en t s (9) Squ ir t a sm a ll a m ou n t of en gin e oil in t o t h e
sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill cylin der s t o lu br ica t e t h e wa lls. Th is will pr even t
wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a da m a ge on r est a r t .
WJ ENGINE - 4.0L 9 - 11
(10) In st a ll n ew spa r k plu gs. Tigh t en t h e spa r k
plu gs t o 41 N·m (30 ft . lbs.) t or qu e.
(11) Dr a in en gin e oil. Rem ove a n d disca r d t h e oil
filt er.
(12) In st a ll t h e dr a in plu g. Tigh t en t h e plu g t o 34
N·m (25 ft . lbs.) t or qu e.
(13) In st a ll a n ew oil filt er.
(14) F ill en gin e cr a n kca se wit h t h e specified
a m ou n t a n d gr a de of oil. (Refer t o LUBRICATION &
MAINTE NANCE - SP E CIF ICATIONS).
(15) Con n ect t h e n ega t ive ca ble(s) t o t h e ba t t er y.
(16) St a r t t h e en gin e a n d ch eck for a n y lea ks.
STANDARD PROCEDURE—CYLINDER BORE

HONING
Befor e h on in g, st u ff plen t y of clea n sh op t owels Fig. 3 Cylinder Bore Crosshatch Pattern
u n der t h e bor es a n d over t h e cr a n ksh a ft t o keep
1 - CROSSHATCH PATTERN
a br a sive m a t er ia ls fr om en t er in g t h e cr a n ksh a ft
2 - INTERSECT ANGLE
a r ea .
(1) Used ca r efu lly, t h e Cylin der Bor e Sizin g H on e
C-823, equ ipped wit h 220 gr it st on es, is t h e best t ool fr ee clot h t o ch eck t h a t t h e bor e is clea n . Oil t h e
for t h is job. In a ddit ion t o degla zin g, it will r edu ce bor es a ft er clea n in g t o pr even t r u st in g.
t a per a n d ou t -of-r ou n d, a s well a s r em ovin g ligh t
scu ffin g, scor in g a n d scr a t ch es. Usu a lly, a few st r okes STANDARD PROCEDURE - ENGINE CORE AND
will clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim - OIL GALLERY PLUGS
it s. Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er,
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p
CAUTION: DO NOT use rigid type hones to remove plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it -
cylinder wall glaze. a ble t ool a n d r em ove plu g (F ig. 4).
(2) Degla zin g of t h e cylin der wa lls m a y be don e if
t h e cylin der bor e is st r a igh t a n d r ou n d. Use a cylin -
der su r fa cin g h on e, H on in g Tool C-3501, equ ipped
wit h 280 gr it st on es (C-3501-3810). a bou t 20-60
st r okes, depen din g on t h e bor e con dit ion , will be su f-
ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Usin g h on in g
oil C-3501-3880, or a ligh t h on in g oil, a va ila ble fr om
m a jor oil dist r ibu t or s.
CAUTION: DO NOT use engine or transmission oil,

mineral spirits, or kerosene.
(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p

a n d down fa st en ou gh t o get a cr ossh a t ch pa t t er n .
Th e h on e m a r ks sh ou ld INTE RSE CT a t 50° t o 60°
for pr oper sea t in g of r in gs (F ig. 3).
(4) A con t r olled h on e m ot or speed bet ween 200 a n d
300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss- Fig. 4 CORE HOLE PLUG REMOVAL
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per 1 - CYLINDER BLOCK
m in u t e ca n be r egu la t ed t o get t h e desir ed 50° t o 60° 2 - REMOVE PLUG WITH PLIERS
a n gle. F a st er u p a n d down st r okes in cr ea se t h e cr oss- 3 - STRIKE HERE WITH HAMMER
h a t ch a n gle. 4 - DRIFT PUNCH
(5) Aft er h on in g, it is n ecessa r y t h a t t h e block be 5 - CUP PLUG
clea n ed t o r em ove a ll t r a ces of a br a sive. Use a br u sh
t o wa sh pa r t s wit h a solu t ion of h ot wa t er a n d det er- CAUTION: Do not drive cup plug into the casting as
gen t . Dr y pa r t s t h or ou gh ly. Use a clea n , wh it e, lin t - restricted cooling can result and cause serious
engine problems.
9 - 12 ENGINE - 4.0L WJ
Th or ou gh ly clea n in side of cu p plu g h ole in cylin - • Oxygen sen sor
der block or h ea d. Be su r e t o r em ove old sea ler. • Ca m sh a ft posit ion sen sor
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r ! • Gen er a t or con n ect or a n d B+ t er m in a l wir e
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g (18) Discon n ect t h e coil r a il elect r ica l con n ect ion s
is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive a n d t h e oil pr essu r e swit ch con n ect or.
plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of (19) P er for m t h e fu el pr essu r e r elea se pr ocedu r e
t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e (Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
lea d-in ch a m fer. STANDARD P ROCE DURE ).
It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t . (20) Discon n ect t h e fu el su pply lin e a t t h e in ject or
Th e coolin g syst em ca n be r efilled a n d t h e veh icle r a il (Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/
pla ced in ser vice im m edia t ely. QUICK CONNE CT F ITTING - STANDARD P ROCE -
DURE ).
REMOVAL (21) Rem ove t h e fu el lin e br a cket fr om t h e in t a ke
(1) Discon n ect t h e ba t t er y n ega t ive ca ble. m a n ifold.
(2) Ma r k t h e h in ge loca t ion s on t h e h ood pa n el for (22) Rem ove t h e a ir clea n er a ssem bly (F ig. 5).
a lign m en t r efer en ce du r in g in st a lla t ion . Rem ove t h e (23) Discon n ect t h e h oses fr om t h e fit t in gs a t t h e
en gin e com pa r t m en t la m p. Rem ove t h e h ood. st eer in g gea r.
(3) Rem ove t h e r a dia t or dr a in cock a n d r a dia t or (24) Dr a in t h e pu m p r eser voir.
ca p t o dr a in t h e coola n t . DO NOT wa st e u sa ble cool- (25) Ca p t h e fit t in gs on t h e h oses a n d st eer in g
a n t . If t h e solu t ion is clea n , dr a in t h e coola n t in t o a gea r t o pr even t for eign object s fr om en t er in g t h e sys-
clea n con t a in er for r eu se. t em .
(4) Rem ove t h e u pper r a dia t or h ose a n d coola n t
r ecover y h ose.
(5) Rem ove t h e lower r a dia t or h ose.
(6) Rem ove u pper r a dia t or su ppor t r et a in in g bolt s
a n d r em ove r a dia t or su ppor t .
(7) Rem ove t h e fa n a ssem bly fr om t h e wa t er pu m p
(Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
RE MOVAL).
(8) Rem ove t h e fa n sh r ou d.
(9) Discon n ect t h e t r a n sm ission flu id cooler lin es
(a u t om a t ic t r a n sm ission ).
(10) Disch a r ge t h e A/C syst em (Refer t o 24 -
H E ATING & AIR CONDITIONING/P LUMBING -
STANDARD P ROCE DURE ).
(11) Rem ove t h e ser vice va lves a n d ca p t h e com -
pr essor por t s.
(12) Rem ove t h e r a dia t or or r a dia t or /con den ser (if
equ ipped wit h A/C).
(13) Discon n ect t h e h ea t er h oses a t t h e en gin e
t h er m ost a t h ou sin g a n d wa t er pu m p.
(14) Discon n ect t h e a cceler a t or ca ble, t r a n sm ission
lin e pr essu r e ca ble a n d speed con t r ol ca ble (if
equ ipped) fr om t h e t h r ot t le body. Fig. 5 Air Cleaner Assembly
(15) Rem ove ca bles fr om t h e br a cket a n d secu r e
1 - POWER STEERING PUMP
ou t of t h e wa y. 2 - AIR CLEANER ASSEMBLY
(16) Discon n ect t h e body gr ou n d a t t h e en gin e.
(17) Discon n ect t h e followin g con n ect or s a n d
secu r e t h eir h a r n ess ou t of t h e wa y. (26) Ra ise a n d su ppor t t h e veh icle.
• P ower st eer in g pr essu r e swit ch (27) Discon n ect t h e wir es fr om t h e en gin e st a r t er
• Coola n t t em per a t u r e sen sor m ot or solen oid.
• Six (6) fu el in ject or con n ect or s (28) Rem ove t h e en gin e st a r t er m ot or (Refer t o 8 -
• In t a ke a ir t em per a t u r e sen sor E LE CTRICAL/STARTING/STARTE R MOTOR -
• Th r ot t le posit ion sen sor RE MOVAL).
• Ma p sen sor (29) Discon n ect t h e oxygen sen sor fr om t h e
• Cr a n ksh a ft posit ion sen sor exh a u st pipe.
WJ ENGINE - 4.0L 9 - 13
(30) Discon n ect t h e exh a u st pipe fr om t h e m a n i- (13) In st a ll t h e exh a u st pipe su ppor t a n d t igh t en
fold. t h e scr ew.
(31) Rem ove t h e exh a u st pipe su ppor t . (14) In st a ll t h e en gin e ben din g br a ce (Refer t o 9 -
(32) Rem ove t h e ben din g br a ce (Refer t o 9 - E NGINE /E NGINE BLOCK/STRUCT SUP P ORT -
E NGINE /E NGINE BLOCK/STRUCT SUP P ORT - INSTALLATION) .
RE MOVAL). (15) Tigh t en t h e en gin e m ou n t -t o-br a cket bolt s.
(33) Rem ove t h e en gin e flywh eel/con ver t er h ou sin g (16) Con n ect t h e veh icle speed sen sor wir e con n ec-
a ccess cover. t ion s a n d t igh t en t h e scr ews.
(34) Ma r k t h e con ver t er a n d dr ive pla t e loca t ion . (17) Con n ect t h e exh a u st pipe t o t h e m a n ifold.
(35) Rem ove t h e con ver t er-t o-dr ive pla t e bolt s. (18) In st a ll t h e en gin e st a r t er m ot or (Refer t o 8 -
(36) Rem ove t h e u pper en gin e flywh eel/con ver t er E LE CTRICAL/STARTING/STARTE R MOTOR -
h ou sin g bolt s a n d loosen t h e bot t om bolt s. INSTALLATION).
(37) Rem ove t h e en gin e m ou n t cu sh ion -t o-en gin e (19) Con n ect t h e wir es t o t h e en gin e st a r t er m ot or
com pa r t m en t br a cket bolt s. solen oid.
(38) Lower t h e veh icle. (20) Lower t h e veh icle.
(39) At t a ch a lift in g device t o t h e en gin e. (21) Con n ect a ll t h e va cu u m h oses a n d wir e con -
(40) Ra ise t h e en gin e off t h e fr on t su ppor t s. n ect or s iden t ified du r in g en gin e r em ova l.
(41) P la ce a su ppor t or floor ja ck u n der t h e con - (22) Rem ove pr ot ect ive ca ps fr om t h e power st eer-
ver t er (or en gin e flywh eel) h ou sin g. in g h oses.
(42) Rem ove t h e r em a in in g con ver t er (or en gin e (23) Con n ect t h e h oses t o t h e fit t in gs a t t h e st eer-
flywh eel) h ou sin g bolt s. in g gea r. Tigh t en t h e n u t t o 52 N·m (38 ft . lbs.)
(43) Lift t h e en gin e ou t of t h e en gin e com pa r t - t or qu e.
m en t . (24) F ill t h e pu m p r eser voir wit h flu id.
(25) In spect t h e fu el su pply lin e o-r in g(s) a n d
INSTALLATION r epla ce if n ecessa r y. Con n ect fu el su pply lin e t o in jec-
t ior r a il a n d ver ify con n ect ion by pu llin g ou t wa r d on
CAUTION: When installing the engine into a vehicle t h e lin e.
equipped with an automatic transmission, be care- (26) In st a ll t h e fu el lin e br a cket t o t h e in t a ke
ful not to damage the trigger wheel on the engine m a n ifold.
flywheel. (27) Con n ect t h e coil r a il elect r ica l con n ect or s a n d
oil pr essu r e swit ch con n ect or.
(1) At t a ch a lift in g device t o t h e en gin e a n d lower (28) Con n ect t h e followin g elect r ica l con n ect or s:
t h e en gin e in t o t h e en gin e com pa r t m en t . F or ea sier • P ower st eer in g pr essu r e swit ch
in st a lla t ion , it m a y be n ecessa r y t o r em ove t h e • Coola n t t em per a t u r e sen sor
en gin e m ou n t br a cket a s a n a id in a lign m en t of t h e • Six (6) fu el in ject or con n ect or s
en gin e t o t h e t r a n sm ission . • In t a ke a ir t em per a t u r e sen sor
(2) Align t h e t r a n sm ission t or qu e con ver t er h ou s- • Th r ot t le posit ion sen sor
in g wit h t h e en gin e. • Ma p sen sor
(3) Loosely in st a ll t h e con ver t er h ou sin g lower • Cr a n ksh a ft posit ion sen sor
bolt s a n d in st a ll t h e n ext h igh er bolt a n d n u t on ea ch • Oxygen sen sor
side. • Ca m sh a ft posit ion sen sor
(4) Tigh t en a ll 4 bolt s fin ger t igh t . • Gen er a t or con n ect or a n d B+ t er m in a l wir e
(5) In st a ll t h e en gin e m ou n t br a cket s (if r em oved). (29) Con n ect a ll pr eviou sly r em oved va cu u m h oses.
(6) Lower t h e en gin e a n d en gin e m ou n t br a cket s (30) Con n ect t h e body gr ou n d st r a p.
on t o t h e en gin e com pa r t m en t cu sh ion s. In st a ll t h e (31) In st a ll t h e t h r ot t le, t r a n sm ission lin e pr es-
bolt s a n d fin ger t igh t en t h e n u t s. su r e, a n d speed con t r ol ca bles t o t h eir m ou n t in g
(7) Rem ove t h e en gin e lift in g device. br a cket a n d con n ect t h em t o t h e t h r ot t le body.
(8) Ra ise a n d su ppor t t h e veh icle. (32) Con n ect t h e h ea t er h oses a t t h e en gin e t h er-
(9) In st a ll t h e r em a in in g en gin e flywh eel/con ver t er m ost a t h ou sin g a n d wa t er pu m p.
h ou sin g bolt s. Tigh t en a ll bolt s t o 38 N·m (28 ft . lbs.) (33) In st a ll t h e fa n a ssem bly (Refer t o 7 - COOL-
t or qu e. ING/E NGINE /RADIATOR FAN - INSTALLATION).
(10) In st a ll t h e con ver t er-t o-dr ive pla t e bolt s. (34) P la ce t h e fa n sh r ou d in posit ion over t h e fa n .
(11) E n su r e t h e in st a lla t ion r efer en ce m a r ks a r e (35) In st a ll t h e r a dia t or (Refer t o 7 - COOLING/
a lign ed. E NGINE /RADIATOR - INSTALLATION).
(12) In st a ll t h e en gin e flywh eel/con ver t er h ou sin g (36) Con n ect t h e ser vice va lves t o t h e A/C com -
a ccess cover. pr essor por t s, if equ ipped wit h A/C.
9 - 14 ENGINE - 4.0L WJ
(37) Ch a r ge t h e a ir con dit ion er syst em (Refer t o 24
DESCRIPTION SPECIFICATION
- H E ATING & AIR CONDITIONING/P LUMBING -
STANDARD P ROCE DURE ). Cylinder Block Cast Iron
(38) Con n ect t h e r a dia t or h oses a n d a u t om a t ic
t r a n sm ission flu id cooler pipes, if equ ipped. Crankshaft Cast Nodular Iron
(39) In st a ll t h e fa n sh r ou d t o t h e r a dia t or or r a di-
a t or /con den ser (if equ ipped wit h A/C). Cylinder Head Cast Iron
(40) In st a ll u pper r a dia t or su ppor t .
Camshaft Cast Iron
(41) Con n ect t h e u pper r a dia t or h ose a n d t igh t en
t h e cla m p. Pistons Aluminum Alloy
(42) Con n ect t h e lower r a dia t or h ose a n d t igh t en
t h e cla m p. Combustion Chamber Dual-Quench
(43) F ill cr a n kca se wit h en gin e oil. (Refer t o
LUBRICATION & MAINTE NANCE /F LUID CAPACI- Connecting Rods Cast Malleable Iron
TIE S - SP E CIF ICATIONS) for cor r ect ca pa cit ies.
(44) F ill t h e coolin g syst em wit h r eu sa ble coola n t CAMSHAFT
or n ew coola n t (Refer t o 7 - COOLING - STANDARD
Hydraulic Tappet Zero Lash
P ROCE DURE ).
Clearance
(45) Align t h e h ood t o t h e scr ibe m a r ks. In st a ll t h e
h ood. Bearing Clearance 0.025 to 0.076 mm
(46) In st a ll t h e a ir clea n er a ssem bly.
(0.001 to 0.003 in.)
(47) In st a ll t h e ba t t er y a n d con n ect t h e ba t t er y
ca ble. Bearing Journal Diameter
WARNING: USE EXTREME CAUTION WHEN THE No. 1 51.54 to 51.56 mm
ENGINE IS OPERATING. DO NOT STAND IN A (2.029 to 2.030 in.)
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR No. 2 51.28 to 51.31 mm
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
(2.019 to 2.020 in.)
NOT WEAR LOOSE CLOTHING.
No. 3 51.03 to 51.05 mm
(48) St a r t t h e en gin e, in spect for lea ks a n d cor r ect (2.009 to 2.010 in.)
t h e flu id levels, a s n ecessa r y.
No. 4 50.78 to 50.80 mm
(1.999 to 2.000 in.)
SPECI FI CAT I ON S
Base Circle Runout 0.03 mm
ENGINE - 4.0L (MAX)
(0.001 in.)
DESCRIPTION SPECIFICATION Valve Lift
Engine Type In-line 6 Cylinder Intake 10.350 mm (0.4075 in.)
Exhaust 10.528 mm (0.4145 in.)
Bore and Stroke 98.4 x 86.69 mm
(3.88 x 3.413 in.) Valve Timing
Displacement 4.0L (242 cu. in.) Intake

Opens 12.4° BTDC
Compression Ratio 8.8:1
Closes 60.9° ABDC
Firing Order 1–5–3–6–2–4 Exhaust
Lubrication Pressure Feed–Full Flow Opens 49.8 BBDC
Filtration Closes 29.2° ATDC
Cooling System Liquid Cooled–Forced Valve Overlap 41.6°

Circulation Intake Duration 253.3°
WJ ENGINE - 4.0L 9 - 15
SPECI FI CAT I ON S (Cont inue d)
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION
Exhaust Duration 259.° Taper 0.025 mm (0.001 in.)

Out-ofRound 0.025 mm (0.001 in.)
CRANKSHAFT
Tappet Bore Diameter 23.000 to 23.025 mm
End Play 0.038 to 0.165 mm
(0.9055 to 0.9065 in.)
(0.0015 to 0.0065 in.)
Flatness 0.03 mm per 25 mm
Main Bearing Journal
Diameter (0.001 in. per 1 in.)
0.05 mm per 152 mm
No. 1-6 63.489 to 63.502 mm
(0.002 in. per 6 in.)
(2.4996 to 2.5001 in.)
No. 7 63.449 to 63.487 mm Flatness Max. 0.20 mm max. for total
length
(2.4980 to 2.4995 in.)
(0.008 in. max. for total
Main Bearing Journal length)
Width
Main Bearing Bore 68.3514 to 68.3768 mm
No. 1 27.58 to 27.89 mm Diameter
(1.086 to 1.098 in.) (2.691 to 2.692 in.)
No. 3 32.28 to 32.33 mm
(1.271 to 1.273 in.) CONNECTING ROD
No. 2-4-5-6-7 30.02 to 30.18 mm Total Weight (Less 663 to 671 grams
(1.182 to 1.188 in.) Bearing)
(23.39 to 23.67 oz.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.) Length (Center-to-Center) 155.52 to 155.62 mm
Preferred 0.051 mm (0.002 in.) (6.123 to 6.127 in.)
Connecting Rod Journal Piston Pin Bore Diameter 23.59 to 23.62 mm

Diameter 53.17 to 53.23 mm (0.9288 to 0.9298 in.)
(2.0934 to 2.0955 in.) Bore (Less Bearings) 56.08 to 56.09 mm
Connecting Rod Journal 27.18 to 27.33 mm (2.2080 to 2.2085 in.)
Width
Bearing Clearance 0.025 to 0.076 mm
(1.070 to 1.076 in.)
(0.001 to 0.003 in.)
Out-of-Round (MAX) 0.013 mm (0.0005 in.) Preferred 0.044 to 0.050 mm
Taper (MAX) 0.013 mm (0.0005 in.) (0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm

CYLINDER BLOCK
(0.010 to 0.019 in.)
Deck Height 240.03 to 240.18 mm
Twist (Max.) 0.002 mm per mm
(9.450 to 9.456 in.)
(0.002 in. per inch)
Deck Clearance (Below 0.546 mm (0.0215 in.)
Block) Bend (Max.) 0.002 mm per mm
(0.002 in. per inch.)
Cylinder Bore Diameter
Standard 98.45 to 98.48 mm CYLINDER COMPRESSION PRESSURE
(3.8759 to 3.8775 in.)
Pressure Range 827 to 1,034 kPa
9 - 16 ENGINE - 4.0L WJ
(120 to 150 psi) VALVES

Max. Variation Between Valve Length (Overall)
Cylinders 206 kPa (30 psi) Intake 122.479 to 122.860 mm
(4.822 to 4.837 in.)
CYLINDER HEAD
Exhaust 122.860 to 123.241 mm
Combustion Chamber 55.22 to 58.22 cc (4.837 to 4.852 in.)
(3.37 to 3.55 cu. in.)
Valve Stem Diameter 7.899 to 7.925 mm
Valve Guide I.D. 7.95 to 7.97 mm (0.311 to 0.312 in.)
(Integral)
(0.313 to 0.314 in.) Stem-to-Guide Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Valve Stem-to-Guide 0.025 to 0.076 mm
Clearance (0.001 to 0.003 in.) Valve Head Diameter
Intake 48.387 to 48.641 mm
Valve Seat Angle
(1.905 to 1.915 in.)
Intake 44.5°
Exhaust 37.973 to 38.227 mm
Exhaust 44.5°
(1.495 to 1.505 in.)
Valve Seat Width 1.02 to 1.52 mm
Valve Face Angle
(0.040 to 0.060 in.)
Intake 46.5°
Valve Seat Runout 0.064 mm (0.0025 in.) Exhaust 46.5°
Flatness 0.03 mm per 25 mm Tip Refinishing (Max. 0.25 mm (0.010 in.)
(0.001 in. per 1 in.) Allowable)
0.05 mm per 152 mm
VALVE SPRINGS
(0.002 in. per 6 in.)
Free Length (Approx.) 47.65 mm (1.876 in.)
Flatness Max. 0.20 mm - max. for total
length Spring Load
(0.008 in. max. for total Valve Closed 316 to 351 N @ 41.656
length) mm
(71 to 79 lbf. @ 1.64 in.)
ROCKER ARMS, PUSH RODS & TAPPETS
Valve Open 898.6 to 969.7 N @
Rocker Arm Ratio 1.6:1 30.89 mm
(202 to 218 lbf @ 1.216
Push Rod Length 244.856 to 245.364 mm
in.)
(Pink) (9.640 to 9.660 in.)
Inside Diameter 21.0 mm to 21.51 mm
Push Rod Diameter 7.92 to 8.00 mm
(0.827 to 0.847 in.)
(0.312 to 0.315 in.)
Installed Height 41.656 mm (1.64 in.)
Hydraulic Tappet 22.962 to 22.974 mm
Diameter PISTONS
(0.904 to 0.9045 in.)
Weight (Less Pin) 417 to 429 grams
Tappet-to-Bore Clearance 0.025 to 0.063 mm (14.7 to 15.1 oz.)
(0.001 to 0.0025 in.)
WJ ENGINE - 4.0L 9 - 17
Piston Pin Bore 40.61 to 40.72 mm OIL PUMP

(Centerline
to Piston Top) (1.599 to 1.603 in.) Gear-to-Body Clearance 0.051 to 0.102 mm
(Radial) (0.002 to (0.004 in.)
Piston-to-Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.) Gear-to-Body Clearance
(Radial) Preferred 0.051 mm (0.002 in.)
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm Gear End Clearance 0.051 to 0.152 mm
(0.0090 to 0.0240 in.) Plastigage (0.002 to 0.006 in.)
2nd Compression Ring 0.483 to 0.965 mm Gear End Clearance
(0.0190 to 0.0380 in.) Plastigage (Preferred) 0.051 mm (0.002 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
Gear End Clearance 0.1016 to 0.2032 mm
(0.010 to 0.060 in.)
Feeler Gauge (0.004 to 0.008 in.)
Ring Side Clearance
Gear End Clearance
Compression Rings 0.042 to 0.084 mm
Feeler Gauge (Preferred) 0.1778 mm (0.007 in.)
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm Oil Pressure
(0.0024 to 0.0083 in.) At Idle Speed 89.6 kPa (13 psi)
Piston Ring Groove At 1600 rpm & Higher 255 to 517 kPa
Height
(37 to 75 psi)
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.) Oil Pressure Relief 517 kPa (75 psi)
Oil Control Ring 4.035 to 4.060 mm
TORQUE - 4.0L ENGINE
(0.1589 to 0.1598 in.)
Piston Ring Groove DESCRIPTION N·m Ft. In.

Diameter
Lbs. Lbs.
No.1 Compression Ring 88.39 to 88.65 mm
A/C Compressor—Bolts 28 — 250
(3.48 to 3.49 in.)
Block Heater—Nut 2 — 16
No.2 Compression Ring 87.63 to 87.88 mm
Camshaft Sprocket—Bolt 68 50 —
(3.45 to 3.46 in.)
Camshaft Thrust Plate to
Oil Control Ring 89.66 to 89.92 mm
(3.53 to 3.54 in.) Cylinder Block—Screws 24 18 —
Clutch Cover to Flywheel— 54 40 —
Piston Pin Bore Diameter 23.650 to 23.658 mm Bolts
(0.9312 to 0.9315 in.) Coil Bracket to Block—Bolts 22 — 192
Piston Pin Diameter 23.637 to 23.640 mm Connecting Rod—Nuts 45 33 —
(0.9306 to 0.9307 in.) Cylinder Block—Drain Plugs 34 25 —
Cylinder Head—Bolts 135 100 —
Piston-to-Pin Clearance 0.0102 to 0.0208 mm
Cylinder Head Cover—Bolts 10 — 85
(0.0005 to 0.0009 in.)
Distributor Clamp—Bolts 23 — 204
Piston-to-Pin Connecting Engine Mounts—Front
Rod (Press Fit) 8.9 kN (2000 lbf.) Support Bracket Bolts 61 45 —
9 - 18 ENGINE - 4.0L WJ
DESCRIPTION N·m Ft. In. DESCRIPTION N·m Ft. In.

Lbs. Lbs. Lbs. Lbs.
Support Cushion Bolts/Nuts 41 30 — Adaptor 47 35 —
Support Cushion Bracket 54 40 — Block 68 50 —
Bolts Adaptor Bolts 102 50 —
Support Cushion Bracket Stud 41 30 — Oil Galley—Plug 41 30 —
Nuts
Oil Pan—Bolts
Support Cushion Thru-Bolt 65 48 —
1/4-20 9.5 — 84
Engine Mounts—Rear
5/16-18 15 — 132
Crossmember to Sill Bolts—
Oil Pan—Drain Plug 34 25 —
(Automatic) 41 30 — Oil Pump
Insulator Stud Assembly—Nut 41 30 — Mounting Bolts 23 — 204
Support Cushion/ Cover Bolts 8 — 70
Crossmember—Nuts 22 — 192 Rocker Arm Assembly to 30 21 —
Support Cushion/Bracket— Cylinder Head—Capscrews
Nuts Spark Plugs 37 27 —
(Manual) 75 55 — Starter Motor—Mounting Bolts 45 33 —
Transmission Support Bracket Thermostat Housing—Bolts 18 — 156
—Bolt (Manual) 46 34 — Throttle Body—Bolts 10 — 90
Transmission Support Bracket/ Vibration Damper—Bolt 108 80 —
Cushion—Bolt (4WD Auto) 75 55 — Water Pump to Block—Bolts 23 17 —
Transmission Support Adaptor
Bracket—Bolts (2WD Auto) 75 55 — AI R CLEAN ER ELEM EN T
Exhaust Manifold/Pipe—Nuts 27 20 —
Intake/Exhaust Manifold REMOVAL - 4.0L
(1) Un la t ch fou r clips r et a in in g a ir clea n er cover t o
Fasteners #1-5 33 24 — a ir clea n er h ou sin g (F ig. 6).
Fasteners #6 and 7 14 — 126 (2) Lift cover u p a n d posit ion t o t h e side.
Fasteners #8-11 33 24 — (3) Rem ove a ir clea n er elem en t .
Flywheel to Converter 38 28 — INSTALLATION - 4.0L

Housing—Bolts (1) Clea n in side of a ir clea n er h ou sin g befor e
Flywheel to Crankshaft—Bolts 143 105 — in st a llin g n ew elem en t .
Front Cover to Block—Bolts (2) In st a ll a ir clea n er elem en t in t o h ou sin g.
(3) La t ch clips a n d cla m p cover down t o secu r e. Be
1/4-20 7 — 60
su r e a ir clea n er cover is pr oper ly sea t ed t o a ir
5/16-18 22 — 192 clea n er h ou sin g.
Fuel Rail—Bolts/Stud 12 — 108
Generator—Bolts 57 42 — AI R CLEAN ER H OU SI N G
Generator Bracket to 47 35 —
Engine—Bolts REMOVAL - 4.0L
Idler Pulley to Cylinder 47 35 — (1) Discon n ect a ir clea n er cover-t o-a ir du ct cla m p
Head—Bolt (F ig. 6).
Main Bearing Cap—Bolts 108 80 — (2) Discon n ect a ir du ct a t h ou sin g.
Oil Filter 18 — 156
Oil Filter Connector to
WJ ENGINE - 4.0L 9 - 19
AI R CLEAN ER H OU SI N G (Cont inue d)
Fig. 7 RESONATOR CLAMP - 4.0L

1 - RESONATOR
2 - AIR DUCT
3 - CLAMP
Fig. 6 Air Cleaner Assembly —4.0L Engine INSTALLATION - 4.0L

1 - RESONATOR BOLTS (1) P osit ion a ir clea n er a ssem bly t o body a n d
2 - CLAMPS in st a ll 3 n u t s. Tigh t en n u t s t o 10 N·m (93 in . lbs.)
3 - AIR DUCT t or qu e. To p re v e n t e x c e s s iv e v ibra tio n tra n s m it-
4 - AIR CLEANER COVER te d th ro u g h h o u s in g , th e n u ts m u s t be p ro p e rly
5 - CLIPS to rqu e d . D o n o t o v e rtig h te n n u ts .
6 - HOUSING (2) If r eson a t or wa s r em oved: In st a ll r eson a t or a n d
7 - HOUSING BOLTS (3) bolt s. Tigh t en bolt s t o 4 N·m (35 in . lbs.) t or qu e.
8 - LOWER HOUSING NUTS (3)
Tigh t en cla m p a t t h r ot t le body t o 4 N·m (35 in . lbs.)
9 - RESONATOR
t or qu e.
(3) P osit ion fen der lin er a n d in st a ll clips.
(3) Ea c h o f th e 3 a ir c le a n e r h o u s in g m o u n t- (4) Con n ect a ir du ct a t h ou sin g (F ig. 6).
in g bo lts is a tta c h e d w ith 2 n u ts (a n u p p e r n u t (5) Tigh t en a ir du ct cla m p.
a n d lo w e r n u t). D O N OT REMOVE B OLTS . To
p re v e n t s trip p in g bo lts , o n ly re m o v e lo w e r
n u ts . Th e lo w e r h o u s in g n u ts a re lo c a te d u n d e r CY LI N DER H EAD
le ft fro n t in n e r fe n d e r (F ig . 6).
(a ) To ga in a ccess t o lower n u t s, r a ise veh icle. DESCRIPTION
(b) Rem ove clips r et a in in g r u bber in n er fen der Th e cylin der h ea d is m a de of ca st ir on con t a in in g
sh ield. t welve va lves m a de of ch r om e pla t ed h ea t r esist a n t
(c) P r y ba ck sh ield en ou gh t o ga in a ccess t o st eel, va lve st em sea ls, spr in gs, r et a in er s a n d keep-
lower n u t s. er s. Th e cylin der h ea d a n d va lve sea t s ca n be r esu r-
(d) Rem ove 3 n u t s. fa ced for ser vice pu r poses.
(e) Rem ove a ir clea n er a ssem bly fr om veh icle. Th e va lve gu ides a r e in t egr a l t o t h e cylin der h ea d,
(4) If r eson a t or is t o be r em oved, discon n ect Th ey a r e n ot r epla cea ble. H owever, t h ey a r e ser vice-
br ea t h er t u be a t r eson a t or, discon n ect a ir du ct cla m p a ble.
a t r eson a t or (F ig. 6)a n d r em ove 1 r eson a t or m ou n t - Th e cylin der h ea d u ses du a l qu en ch -t ype design
in g bolt . Rem ove r eson a t or fr om t h r ot t le body by com bu st ion ch a m ber s wh ich ca u se t u r bu len ce in t h e
loosen in g cla m p (F ig. 7).
9 - 20 ENGINE - 4.0L WJ
CY LI N DER H EAD (Cont inue d)
cylin der s a llowin g fa st er bu r n in g of t h e a ir /fu el m ix- (7) Rem ove t h e a ccessor y dr ive belt (Refer t o 7 -
t u r e, r esu lt in g in bet t er fu el econ om y (F ig. 8). COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(8) Rem ove t h e A/C com pr essor m ou n t in g bolt s
a n d secu r e t h e com pr essor t o t h e side.
(9) Rem ove t h e power st eer in g pu m p a n d br a cket
fr om t h e in t a ke m a n ifold a n d wa t er pu m p. Set t h e
pu m p a n d br a cket a side. DO NOT discon n ect t h e
h oses.
(10) P er for m t h e F u el Syst em P r essu r e Relea se
pr ocedu r e. (Refer t o 14 - F UE L SYSTE M/F UE L
DE LIVE RY - STANDARD P ROCE DURE ).
(11) Discon n ect t h e fu el su pply lin e a t t h e fu el r a il.
(12) Rem ove t h e in t a ke a n d exh a u st m a n ifolds
fr om t h e en gin e cylin der h ea d (Refer t o 9 - E NGINE /
MANIF OLDS/INTAKE MANIF OLD - RE MOVAL).
(13) Rem ove t h e coil r a il (Refer t o 8 - E LE CTRI-
CAL/IGNITION CONTROL/COIL RAIL - RE MOV-
AL).
Fig. 8 Cylinder Head 4.0L Engine
(14) Rem ove spa r k plu gs (Refer t o 8 - E LE CTRI-
1 - CYLINDER HEAD BOLTS CAL/IGNITION CONTROL/SPARK P LUG - RE MOV-
2 - CYLINDER HEAD GASKET
AL).
3 - CYLINDER HEAD
(15) Discon n ect t h e t em per a t u r e sen din g u n it wir e
con n ect or.
REMOVAL (16) Rem ove t h e en gin e cylin der h ea d bolt s. Bolt
No.14 ca n n ot be r em oved u n t il t h e h ea d is m oved for-
NOTE: This procedure can be done with the engine wa r d (F ig. 9) . P u ll bolt No.14 ou t a s fa r a s it will go
in or out of the vehicle. a n d t h en su spen d t h e bolt in t h is posit ion (t a pe
a r ou n d t h e bolt ).
(1) Discon n ect t h e ba t t er y n ega t ive ca ble. (17) Rem ove t h e en gin e cylin der h ea d a n d ga sket
(F ig. 9).
WARNING: DO NOT REMOVE THE CYLINDER (18) If t h is wa s t h e fir st t im e t h e bolt s wer e
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR r em oved, pu t a pa in t da b on t h e t op of t h e bolt . If t h e
DRAIN COCK WITH THE SYSTEM HOT AND PRES- bolt s h a ve a pa in t da b on t h e t op of t h e bolt or it
SURIZED BECAUSE SERIOUS BURNS FROM THE isn ’t kn own if t h ey wer e u sed befor e, disca r d t h e
COOLANT CAN OCCUR. bolt s.
(19) St u ff clea n lin t fr ee sh op t owels in t o t h e cyl-
(2) Dr a in t h e coola n t (Refer t o 7 - COOLING - in der bor es.
STANDARD P ROCE DURE ) a n d discon n ect t h e h oses
a t t h e en gin e t h er m ost a t h ou sin g a n d t h e wa t er NOTE: If the valves, springs, or seals are to be
pu m p in let . DO NOT wa st e r eu sa ble coola n t . If t h e inspected/replaced at this time, (Refer to 9 -
solu t ion is clea n a n d is bein g dr a in ed on ly t o ser vice ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
t h e en gin e or coolin g syst em , dr a in t h e coola n t in t o a VALVES & SEATS - STANDARD PROCEDURE) for
clea n con t a in er for r eu se. proper inspection procedures.
(3) Rem ove t h e a ir clea n er a ssem bly (Refer t o 9 -
E NGINE /AIR INTAKE SYSTE M/AIR CLE ANE R
H OUSING - RE MOVAL). CLEANING
(4) Rem ove t h e cylin der h ea d cover (Refer t o 9 - Th or ou gh ly clea n t h e en gin e cylin der h ea d a n d cyl-
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD in der block m a t in g su r fa ces. Clea n t h e in t a ke a n d
COVE R(S) - RE MOVAL). en gin e exh a u st m a n ifold a n d en gin e cylin der h ea d
(5) Rem ove t h e ca pscr ews, br idge a n d pivot a ssem - m a t in g su r fa ces. Rem ove a ll ga sket m a t er ia l a n d ca r-
blies a n d r ocker a r m s (Refer t o 9 - E NGINE /CYLIN- bon .
DE R H E AD/ROCKE R ARM / ADJ USTE R ASSY - Ch eck t o en su r e t h a t n o coola n t or for eign m a t er ia l
RE MOVAL). h a s fa llen in t o t h e t a ppet bor e a r ea .
(6) Rem ove t h e pu sh r ods. Re ta in th e p u s h ro d s , Rem ove t h e ca r bon deposit s fr om t h e com bu st ion
brid g e s , p iv o ts a n d ro c k e r a rm s in th e s a m e ch a m ber s a n d t op of t h e pist on s.
o rd e r a s re m o v e d .
WJ ENGINE - 4.0L 9 - 21
(4) Coa t t h e t h r ea ds of st u d bolt No.11 wit h Loc-
t it e 592 sea la n t , or equ iva len t .
(5) Tigh t en t h e en gin e cylin der h ea d bolt s in
sequ en ce a ccor din g t o t h e followin g pr ocedu r e (F ig.
10).
CAUTION: During the final tightening sequence,

bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a ) Tigh t en a ll bolt s in sequ en ce (1 t h r ou gh 14)

t o 30 N·m (22 ft . lbs.) t or qu e.
(b) Tigh t en a ll bolt s in sequ en ce (1 t h r ou gh 14)
t o 61 N·m (45 ft . lbs.) t or qu e.
(c) Ch eck a ll bolt s t o ver ify t h ey a r e set t o 61
Fig. 9 Engine Cylinder
(d) Tigh t en bolt s in sequ en ce:
1 - CYLINDER HEAD BOLTS • Bolt s 1 t h r ou gh 10 t o 149 N·m (110 ft . lbs.)
2 - CYLINDER HEAD GASKET
t or qu e.
3 - CYLINDER HEAD
• Bolt 11 t o 135 N·m (100 ft . lbs.) t or qu e.
• Bolt s 12 t h r ou gh 14 t o 149 N·m (110 ft . lbs.)
INSPECTION t or qu e.
Use a st r a igh t edge a n d feeler ga u ge t o ch eck t h e CY LI N DER H EAD BOLT S
fla t n ess of t h e en gin e cylin der h ea d a n d block m a t in g
su r fa ces. POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
INSTALLATION
8,9 1/2 in.-13 BOLT WITH DOWEL
NOTE: This procedure can be done with the engine POINT
in or out of the vehicle. 2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
Th e en gin e cylin der h ea d ga sket is a com posit ion
All bolts are 12 point drives for rocker cover clearance
ga sket . Th e ga sket is t o be in st a lled DRY. D O N OT
u s e a g a s k e t s e a lin g c o m p o u n d o n th e g a s k e t.
(e) Ch eck a ll bolt s in sequ en ce t o ver ify t h e cor-
If t h e en gin e cylin der h ea d is t o be r epla ced a n d
r ect t or qu e.
t h e or igin a l va lves u sed, m ea su r e t h e va lve st em
(f) If n ot a lr ea dy don e, clea n a n d m a r k ea ch bolt
dia m et er. On ly st a n da r d size va lves ca n be u sed wit h
wit h a da b of pa in t a ft er t igh t en in g. Sh ou ld you
a ser vice r epla cem en t en gin e cylin der h ea d u n less
en cou n t er bolt s wh ich wer e pa in t ed in a n ea r lier
t h e r epla cem en t h ea d va lve st em gu ide bor es a r e
ser vice oper a t ion , r epla ce t h em .
r ea m ed t o a ccom m oda t e over size va lve st em s.
Rem ove a ll ca r bon bu ildu p a n d r efa ce t h e va lves.
(1) Rem ove t h e sh op t owels fr om t h e cylin der
bor es. Coa t t h e bor es wit h clea n en gin e oil.
(2) P osit ion t h e en gin e cylin der h ea d ga sket (wit h
t h e n u m ber s fa cin g u p) u sin g t h e a lign m en t dowels
in t h e cylin der block, t o posit ion t h e ga sket .
CAUTION: Engine cylinder head bolts should be

reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
Fig. 10 Engine Cylinder Head Bolt Tightening
(3) Wit h bolt No.14 h eld in pla ce (t a pe a r ou n d Sequence
bolt ), in st a ll t h e en gin e cylin der h ea d over t h e sa m e
dowels u sed t o loca t e t h e ga sket . Rem ove t h e t a pe
fr om bolt No.14.
9 - 22 ENGINE - 4.0L WJ
(6) In st a ll t h e spa r k plu gs (Refer t o 8 - E LE CTRI- LINE WITH THE FAN. DO NOT PUT HANDS NEAR
CAL/IGNITION CONTROL/SPARK P LUG - INSTAL- THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LATION). LOOSE CLOTHING.
(7) Con n ect t h e t em per a t u r e sen din g u n it wir e
con n ect or. (23) Oper a t e t h e en gin e wit h t h e r a dia t or ca p off.
(8) In st a ll t h e ign it ion coil r a il (Refer t o 8 - E LE C- In spect for lea ks a n d con t in u e oper a t in g t h e en gin e
TRICAL/IGNITION CONTROL/COIL RAIL - u n t il t h e en gin e t h er m ost a t open s. Add coola n t , if
INSTALLATION). r equ ir ed.
(9) In st a ll t h e in t a ke a n d exh a u st m a n ifolds (Refer
t o 9 - E NGINE /MANIF OLDS/INTAKE MANIF OLD -
INSTALLATION). CY LI N DER H EAD COV ER(S)
(10) In st a ll t h e fu el lin e.
(11) At t a ch t h e power st eer in g pu m p a n d br a cket . DESCRIPTION
(12) In st a ll t h e pu sh r ods, r ocker a r m s, pivot s a n d Th e cylin der h ea d cover (F ig. 11) is m a de of
br idges in t h e or der t h ey wer e r em oved (Refer t o 9 - st a m ped st eel a n d in cor por a t es t h e Cr a n kca se Ven t i-
E NGINE /CYLINDE R H E AD/ROCKE R ARM / la t ion (CCV) H oses a n d t h e oil fill open in g.
ADJ USTE R ASSY - INSTALLATION).
(13) In st a ll t h e en gin e cylin der h ea d cover (Refer
t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R
H E AD COVE R(S) - INSTALLATION).
(14) At t a ch t h e a ir con dit ion er com pr essor m ou n t -
in g br a cket t o t h e en gin e cylin der h ea d a n d block.
Tigh t en t h e bolt s t o 40 N·m (30 ft . lbs.) t or qu e.
(15) At t a ch t h e a ir con dit ion in g com pr essor t o t h e
br a cket . Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.)
t or qu e.
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) In st a ll t h e ser pen t in e dr ive belt . (Refer t o 7 - Fig. 11 Cylinder Head Cover
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION). REMOVAL
(17) In st a ll t h e a ir clea n er a n d du ct in g. Th e cylin der h ea d cover is isola t ed fr om t h e cylin -
(18) Con n ect t h e h oses t o t h e en gin e t h er m ost a t der h ea d via gr om m et s a n d a r eu sa ble m olded r u bber
h ou sin g a n d fill t h e coolin g syst em t o t h e specified ga sket . Th e gr om m et a n d lim it er a r e r et a in ed in t h e
level (Refer t o 7 - COOLING - STANDARD P ROCE - cylin der h ea d cover.
DURE ). (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(19) Th e a u t om a t ic t r a n sm ission t h r ot t le lin ka ge (2) Discon n ect t h e Cr a n kca se Ven t ila t ion (CCV)
a n d ca ble m u st be a dju st ed a ft er com plet in g t h e va cu u m h ose fr om en gin e cylin der h ea d cover.
en gin e cylin der h ea d in st a lla t ion (Refer t o 21 - (3) Discon n ect t h e fr esh a ir in let h ose fr om t h e
TRANSMISSION/TRANSAXLE /AUTOMATIC - AW4/ en gin e cylin der h ea d cover.
TH ROTTLE VALVE CABLE - ADJ USTME NTS). (4) Discon n ect t h e a cceler a t or, t r a n sm ission , a n d
(20) In st a ll t h e t em per a t u r e sen din g u n it a n d con - speed (if equ ipped) con t r ol ca bles fr om t h e t h r ot t le
n ect t h e wir e con n ect or. body (F ig. 12).
(21) If equ ipped wit h a ir con dit ion in g, in st a ll A/C (5) Rem ove t h e t h r ee bolt s t h a t fa st en t h e con t r ol
com pr essor (Refer t o 24 - H E ATING & AIR CONDI- ca ble br a cket t o t h e in t a ke m a n ifold.
TIONING/P LUMBING/A/C COMP RE SSOR - (6) Rem ove con t r ol ca bles fr om cylin der h ea d cover
INSTALLATION) a n d ch a r ge A/C syst em (Refer t o 24 clip.
- H E ATING & AIR CONDITIONING/P LUMBING - (7) P osit ion con t r ol ca bles a n d br a cket a wa y fr om
STANDARD P ROCE DURE ). cylin der h ea d cover secu r e wit h t ie st r a ps.
(22) Con n ect n ega t ive ca ble t o ba t t er y. (8) Rem ove t h e en gin e cylin der h ea d cover m ou n t -
in g bolt s.
WARNING: USE EXTREME CAUTION WHEN THE (9) Rem ove t h e en gin e cylin der h ea d cover a n d
ENGINE IS OPERATING. DO NOT STAND IN DIRECT ga sket .
WJ ENGINE - 4.0L 9 - 23
CY LI N DER H EAD COV ER(S) (Cont inue d)
Fig. 13 Cylinder Head Cover Gasket Locator Pins at

#8 & #9
(4) In st a ll con t r ol ca bles a n d br a cket on in t a ke
m a n ifold a n d t igh t en bolt s t o 8.7 N·m (77 in . lbs.)
Fig. 12 Engine Cylinder Head Cover t or qu e.
1 - TRANS CONTROL CABLE (5) Con n ect con t r ol ca bles t o t h r ot t le body lin ka ge.
2 - ACCELERATOR CABLE (6) Sn a p con t r ol ca bles in t o cylin der h ea d cover
3 - CONTROL CABLE BRACKET clip.
4 - CYLINDER HEAD COVER (7) Con n ect n ega t ive ca ble t o ba t t er y.
CLEANING I N TAK E/EX H AU ST VALV ES &

Rem ove a n y or igin a l sea ler fr om t h e cover sea lin g
su r fa ce of t h e en gin e cylin der h ea d a n d clea n t h e
SEAT S
su r fa ce u sin g a fa br ic clea n er.
Rem ove a ll r esidu e fr om t h e sea lin g su r fa ce u sin g DESCRIPTION
a clea n , dr y clot h . Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. All
INSPECTION va lves u se t h r ee bea d locks t o pr om ot e va lve r ot a t ion
In spect t h e en gin e cylin der h ea d cover for cr a cks. (F ig. 14).
Repla ce t h e cover, if cr a cked.
Th e or igin a l da r k gr ey ga sket m a t er ia l sh ou ld STANDARD PROCEDURE - VALVE SERVICE
NOT be r em oved. If sect ion s of t h e ga sket m a t er ia l
a r e m issin g or a r e com pr essed, r epla ce t h e en gin e VALVE REFACING
cylin der h ea d cover. H owever, sect ion s wit h m in or Clea n a ll ca r bon deposit s fr om t h e com bu st ion
da m a ge su ch a s sm a ll cr a cks, cu t s or ch ips m a y be ch a m ber s, va lve por t s, va lve st em s, va lve st em
r epa ir ed wit h a h a n d h eld a pplica t or. Th e n ew m a t e- gu ides a n d h ea d.
r ia l m u st be sm oot h ed over t o m a in t a in ga sket (1) Use a va lve r efa cin g m a ch in e t o r efa ce t h e
h eigh t . Allow t h e ga sket m a t er ia l t o cu r e pr ior t o in t a ke a n d exh a u st va lves t o t h e specified a n gle.
en gin e cylin der h ea d cover in st a lla t ion . (2) Aft er r efa cin g, a m a r gin of a t lea st 0.787 m m
(0.031 in ch ) m u st r em a in (F ig. 15). If t h e m a r gin is
INSTALLATION less t h a n 0.787 m m (0.031 in ch ), t h e va lve m u st be
Th e cylin der h ea d cover is isola t ed fr om t h e cylin - r epla ced.
der h ea d via gr om m et s a n d a r eu sa ble m olded r u bber
ga sket . Th e gr om m et a n d lim it er a r e r et a in ed in t h e
VALVE SEAT REFACING
cylin der h ea d cover. Clea n a ll ca r bon deposit s fr om t h e com bu st ion
(1) If a r epla cem en t cover is in st a lled, t r a n sfer t h e ch a m ber s, va lve por t s, va lve st em s, va lve st em
CCV va lve gr om m et a n d oil filler ca p fr om t h e or igi- gu ides a n d h ea d.
n a l cover t o t h e r epla cem en t cover. (1) In st a ll a pilot of t h e cor r ect size in t h e va lve
(2) In st a ll cylin der h ea d cover a n d ga sket (F ig. 13). gu ide bor e. Refa ce t h e va lve sea t t o t h e specified
Tigh t en t h e m ou n t in g bolt s t o 10 N·m (85 in . lbs.) a n gle wit h a good dr essin g st on e. Rem ove on ly
t or qu e. en ou gh m et a l t o pr ovide a sm oot h fin ish .
(3) Con n ect t h e CCV h oses. (2) Use t a per ed st on es t o obt a in t h e specified sea t
widt h wh en r equ ir ed.
9 - 24 ENGINE - 4.0L WJ
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
Fig. 16 Measurement of Valve Seat Runout

1 - DIAL INDICATOR
VALVE STEM-TO-GUIDE CLEARANCE

Fig. 14 VALVE AND KEEPER CONFIGURATION 4.0L MEASUREMENT
1 - VALVE LOCKS (3–BEAD)
PREFERRED METHOD
2 - RETAINER
3 - VALVE STEM OIL SEAL (1) Rem ove t h e va lve fr om t h e h ea d.
4 - INTAKE VALVE (2) Clea n t h e va lve st em gu ide bor e wit h solven t
5 - EXHAUST VALVE a n d a br ist le br u sh .
6 - VALVE SPRING (3) In ser t a t elescopin g ga u ge in t o t h e va lve st em
gu ide bor e a ppr oxim a t ely 9.525 m m (.375 in ch ) fr om
t h e va lve spr in g side of t h e h ea d (F ig. 17).
(4) Rem ove a n d m ea su r e t elescopin g ga u ge wit h a
m icr om et er.
(5) Repea t t h e m ea su r em en t wit h con t a ct s len gt h -
wise t o en gin e cylin der h ea d.
(6) Com pa r e t h e cr osswise t o len gt h wise m ea su r e-
m en t s t o det er m in e ou t -of-r ou n dn ess. If t h e m ea su r e-
m en t s differ by m or e t h a n 0.0635 m m (0.0025 in .),
r ea m t h e gu ide bor e t o a ccom m oda t e a n over size
va lve st em .
(7) Com pa r e t h e m ea su r ed va lve gu ide bor e dia m -
et er wit h specifica t ion s (7.95-7.97 m m or 0.313-0.314
in ch ). If t h e m ea su r em en t differ s fr om specifica t ion
by m or e t h a n 0.076 m m (0.003 in ch ), r ea m t h e gu ide
bor e t o a ccom m oda t e a n over size va lve st em .
ALTERNATIVE METHOD
Fig. 15 Valve Facing (1) Use a dia l in dica t or t o m ea su r e t h e la t er a l
m ovem en t of t h e va lve st em (st em -t o-gu ide clea r-
1 - VALVE MARGIN
2 - NO MARGIN
a n ce). Th is m u st be don e wit h t h e va lve in st a lled in
it s gu ide a n d ju st off t h e va lve sea t (F ig. 18).
(2) Cor r ect clea r a n ce is 0.025-0.0762 mm
(3) Con t r ol va lve sea t r u n ou t t o a m a xim u m of (0.001-0.003 in ch ). If in dica t ed m ovem en t exceeds t h e
0.0635 m m (0.0025 in .) (F ig. 16). specifica t ion r ea m t h e va lve gu ide t o a ccom m oda t e
a n over size va lve st em .
WJ ENGINE - 4.0L 9 - 25
(1) Rem ove t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL) fr om t h e
cylin der block.
(2) Use Va lve Spr in g Com pr essor Tool
MD-998772A a n d com pr ess ea ch va lve spr in g.
(3) Rem ove t h e va lve locks, r et a in er s, spr in gs a n d
va lve st em oil sea ls. Disca r d t h e oil sea ls (F ig. 19).
(4) Use a sm oot h st on e or a jeweler s file t o r em ove
a n y bu r r s on t h e t op of t h e va lve st em , especia lly
a r ou n d t h e gr oove for t h e locks.
(5) Rem ove t h e va lves, a n d pla ce t h em in a r a ck in
t h e sa m e or der a s r em oved.
Fig. 17 Measurement of Valve Guide Bore Diameter

1 - GAUGE
2 - 9.525 MM (3/8 INCH)
3 - VALVE STEM GUIDE
4 - CYLINDER HEAD
NOTE: Valve seats must be ground after reaming

the valve guides to ensure that the valve seat is
concentric to the valve guide.
Fig. 19 Valve and Valve Components

2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
INSTALLATION
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.
Fig. 18 Measurement of Lateral Movement Of Valve (1) Th or ou gh ly clea n t h e va lve st em s a n d t h e va lve

Stem gu ide bor es.
1 - DIAL INDICATOR (2) Ligh t ly lu br ica t e t h e st em .
(3) In st a ll t h e va lve in t h e or igin a l va lve gu ide
bor e.
REMOVAL (4) In st a ll t h e r epla cem en t va lve st em oil sea ls on
t h e va lve st em s (F ig. 20). If t h e 0.381 m m (0.015
NOTE: This procedure is done with the engine cylin ch ) over size va lve st em s a r e u sed, over size oil sea ls
inder head removed from the block. a r e r equ ir ed.
9 - 26 ENGINE - 4.0L WJ
(5) P osit ion t h e va lve spr in g a n d r et a in er on t h e
en gin e cylin der h ea d a n d com pr ess t h e va lve spr in g
wit h Va lve Spr in g Com pr essor Tool MD-998772A.
(6) In st a ll t h e va lve locks a n d r elea se t h e t ool.
(7) Ta p t h e va lve spr in g fr om side t o side wit h a
h a m m er t o en su r e t h a t t h e spr in g is pr oper ly sea t ed
a t t h e en gin e cylin der h ea d. Also t a p t h e t op of t h e
r et a in er t o sea t t h e va lve locks.
(8) In st a ll t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION).
Fig. 21 Rocker Arms—Typical

1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
2 - RETAINER
(1) Rem ove t h e cylin der h ea d cover (Refer t o 9 -
4 - INTAKE VALVE
5 - EXHAUST VALVE
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
6 - VALVE SPRING COVE R(S) - RE MOVAL).
(2) Ch eck for r ocker a r m br idges wh ich a r e ca u s-
in g m isa lign m en t of t h e r ocker a r m t o va lve t ip a r ea .
ROCK ER ARM / ADJ U ST ER (3) Rem ove t h e ca pscr ews a t ea ch br idge a n d pivot
a ssem bly (F ig. 22). Alt er n a t ely loosen t h e ca pscr ews
ASSEM BLY on e t u r n a t a t im e t o a void da m a gin g t h e br idges.
(4) Rem ove t h e br idges, pivot s a n d cor r espon din g
DESCRIPTION pa ir s of r ocker a r m s (F ig. 22). P la ce t h em on a ben ch
Th e r ocker a r m s a r e m a de of st a m ped st eel a n d in t h e sa m e or der a s r em oved.
h a ve a oper a t ion a l r a t io of 1.6:1 (F ig. 21). (5) Rem ove t h e pu sh r ods a n d pla ce t h em on a
ben ch in t h e sa m e or der a s r em oved.
OPERATION
Wh en t h e pu sh r ods a r e for ced u pwa r d by t h e ca m - CLEANING
sh a ft lobes t h e pu sh r od pr esses u pwa r d on t h e Clea n a ll t h e com pon en t s wit h clea n in g solven t .
r ocker a r m s, t h e r ocker a r m s pivot , for cin g down - Use com pr essed a ir t o blow ou t t h e oil pa ssa ges in
wa r d pr essu r e on t h e va lves for cin g t h e va lves t o t h e r ocker a r m s a n d pu sh r ods.
m ove down wa r d a n d off fr om t h eir sea t s.
WJ ENGINE - 4.0L 9 - 27
ROCK ER ARM / ADJ U ST ER ASSEM BLY (Cont inue d)
(1) Lu br ica t e t h e ba ll en ds of t h e pu sh r ods wit h
Mopa r ! E n gin e Oil Su pplem en t , or equ iva len t a n d
in st a ll pu sh r ods in t h eir or igin a l loca t ion s. E n su r e
t h a t t h e bot t om en d of ea ch pu sh r od is cen t er ed in
t h e t a ppet plu n ger ca p sea t .
(2) Usin g Mopa r ! E n gin e Oil Su pplem en t , or
equ iva len t , lu br ica t e t h e a r ea of t h e r ocker a r m t h a t
t h e pivot con t a ct s. In st a ll r ocker a r m s, pivot s a n d
br idge a bove ea ch cylin der in t h eir or igin a lly posit ion
(F ig. 23).
(3) Loosely in st a ll t h e ca pscr ews t h r ou gh ea ch
br idge.
(4) At ea ch br idge, t igh t en t h e ca pscr ews a lt er-
n a t ely, on e t u r n a t a t im e, t o a void da m a gin g t h e
br idge. Tigh t en t h e ca pscr ews t o 28 N·m (21 ft . lbs.)
t or qu e.
(5) In st a ll t h e en gin e cylin der h ea d cover (Refer t o
9 - E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION).
Fig. 22 Rocker Arm

1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
INSPECTION
In spect t h e pivot su r fa ce a r ea of ea ch r ocker a r m .
Repla ce a n y t h a t a r e scu ffed, pit t ed, cr a cked or
excessively wor n .
In spect t h e va lve st em t ip con t a ct su r fa ce of ea ch
r ocker a r m a n d r epla ce a n y r ocker a r m t h a t is deeply
pit t ed.
In spect ea ch pu sh r od en d for excessive wea r a n d
r epla ce a s r equ ir ed. If a n y pu sh r od is excessively
wor n beca u se of la ck of oil, r epla ce it a n d in spect t h e
cor r espon din g h ydr a u lic t a ppet for excessive wea r.
In spect t h e pu sh r ods for st r a igh t n ess by r ollin g
t h em on a fla t su r fa ce or by sh in in g a ligh t bet ween Fig. 23 Rocker Arm
t h e pu sh r od a n d t h e fla t su r fa ce. 1 - CAPSCREWS
A wea r pa t t er n a lon g t h e len gt h of t h e pu sh r od is 2 - BRIDGE
n ot n or m a l. In spect t h e en gin e cylin der h ea d for 3 - PIVOT ASSEMBLY
4 - PUSH RODS
obst r u ct ion if t h is con dit ion exist s.
5 - ROCKER ARMS
INSTALLATION
in or out of the vehicle.
9 - 28 ENGINE - 4.0L WJ
VALV E ST EM SEALS
DESCRIPTION
Th e va lve st em sea ls (F ig. 24) a r e m a de of r u bber
a n d in cor por a t e a ga r t er spr in g t o m a in t a in con sis-
t en t lu br ica t ion con t r ol.
Fig. 25 VALVE AND KEEPER CONFIGURATION 4.0L

2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 24 Valve
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
VALV E SPRI N GS
DESCRIPTION
Th e va lve spr in gs (F ig. 25) a r e m a de of h igh
st r en gt h silicon ch r om e spr in g st eel. Th e spr in gs a r e
com m on for bot h in t a ke a n d exh a u st va lves.
STANDARD PROCEDURE - VALVE SPRING

TENSION TEST Fig. 26 Valve Spring Tester
Clea n a ll ca r bon deposit s fr om t h e com bu st ion 1 - TORQUE WRENCH
ch a m ber s, va lve por t s, va lve st em s, va lve st em 2 - VALVE SPRING TESTER
gu ides a n d h ea d.
Use a u n iver sa l Va lve Spr in g Test er a n d a t or qu e
wr en ch t o t est ea ch va lve spr in g for t h e specified t en - REMOVAL
sion va lu e (F ig. 26).
Repla ce va lve spr in gs t h a t a r e n ot wit h in specifica -
cylinder head installed on the block.
t ion s.
WJ ENGINE - 4.0L 9 - 29
VALV E SPRI N GS (Cont inue d)
In spect t h e va lve st em s, especia lly t h e gr ooves. An
Ar ka n sa s sm oot h st on e sh ou ld be u sed t o r em ove
n icks a n d h igh spot s.
E a ch va lve spr in g is h eld in pla ce by a r et a in er
a n d a set of con ica l va lve locks. Th e locks ca n be
r em oved on ly by com pr essin g t h e va lve spr in g.
(1) Rem ove t h e en gin e cylin der h ea d cover (Refer
H E AD COVE R(S) - RE MOVAL).
(2) Rem ove ca p scr ews, br idge a n d pivot a ssem -
blies a n d r ocker a r m s (Refer t o 9 - E NGINE /CYLIN-
DE R H E AD/ROCKE R ARM / ADJ USTE R ASSY -
RE MOVAL) for a ccess t o ea ch va lve spr in g t o be
r em oved.
(3) Rem ove pu sh r ods. Re ta in th e p u s h ro d s ,
brid g e s , p iv o ts a n d ro c k e r a rm s in th e s a m e
o rd e r a n d p o s itio n a s re m o v e d .
(4) In spect t h e spr in gs a n d r et a in er for cr a cks a n d
possible sign s of wea ken in g.
(5) Rem ove t h e spa r k plu g(s) a dja cen t t o t h e cylin -
der (s) below t h e va lve spr in gs t o be r em oved.
(6) Con n ect a n a ir h ose t o t h e a da pt er a n d a pply
a ir pr essu r e slowly. Ma in t a in a t lea st 621 kP a (90
psi) of a ir pr essu r e in t h e cylin der t o h old t h e va lves
2 - RETAINER
a ga in st t h eir sea t s. F or veh icles equ ipped wit h a n a ir
con dit ion er, u se a flexible a ir a da pt or wh en ser vicin g 4 - INTAKE VALVE
t h e No.1 cylin der. 5 - EXHAUST VALVE
(7) Ta p t h e r et a in er or t ip wit h a r a wh ide h a m m er 6 - VALVE SPRING
t o loosen t h e lock fr om t h e r et a in er. Use Va lve Spr in g
Com pr essor Tool MD-998772A t o com pr ess t h e spr in g
a n d r em ove t h e locks (F ig. 27). t h e spr in g is sea t ed pr oper ly on t h e en gin e cylin der
(8) Rem ove va lve spr in g a n d r et a in er (F ig. 27). h ea d.
(9) Rem ove va lve st em oil sea ls (F ig. 27). Not e t h e (4) Relea se a ir pr essu r e a n d discon n ect t h e a ir
va lve sea ls a r e differ en t for in t a ke a n d exh a u st h ose. Rem ove t h e a da pt or fr om t h e spa r k plu g h ole
va lves. Th e t op of ea ch sea l is m a r ked eit h er INT a n d in st a ll t h e spa r k plu g.
(in t a ke/bla ck in color ) or E XH (exh a u st /br own in (5) Repea t t h e pr ocedu r es for ea ch r em a in in g va lve
color ). DO NOT m ix t h e sea ls. spr in g t o be r em oved.
(6) In st a ll t h e pu sh r ods. E n su r e t h e bot t om en d of
ea ch r od is cen t er ed in t h e plu n ger ca p sea t of t h e
INSTALLATION
h ydr a u lic va lve t a ppet .
NOTE: This procedure can be done with the engine (7) In st a ll t h e r ocker a r m s, pivot s a n d br idge
cylinder head installed on the block. (Refer t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R
ARM / ADJ USTE R ASSY - INSTALLATION) a t t h eir
or igin a l loca t ion .
CAUTION: Install oil seals carefully to prevent dam- (8) In st a ll t h e en gin e cylin der h ea d cover (Refer t o
age from the sharp edges of the valve spring lock 9 - E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
grove. COVE R(S) - INSTALLATION).
(1) Ligh t ly pu sh t h e va lve sea l over t h e va lve st em

a n d va lve gu ide boss. Be su r e t h e sea l is com plet ely EN GI N E BLOCK
sea t ed on t h e va lve gu ide boss.
(2) In st a ll va lve spr in g a n d r et a in er (F ig. 28). CLEANING
(3) Com pr ess t h e va lve spr in g wit h Va lve Spr in g Th or ou gh ly clea n t h e oil pa n a n d en gin e block ga s-
Com pr essor Tool MD-998772A a n d in ser t t h e va lve ket su r fa ces.
locks. Relea se t h e spr in g t en sion a n d r em ove t h e Use com pr essed a ir t o clea n ou t :
t ool. Ta p t h e spr in g fr om side-t o-side t o en su r e t h a t • Th e ga lley a t t h e oil filt er a da pt or h ole.
• Th e fr on t a n d r ea r oil ga lley h oles.
9 - 30 ENGINE - 4.0L WJ
EN GI N E BLOCK (Cont inue d)
Fig. 28 Valve and Valve

Fig. 29 Cylinder Bore Measurement
2 - RETAINER (7) If cylin der bor e t a per does n ot exceed 0.025
3 - VALVE STEM OIL SEAL m m (0.001 in ch ) a n d ou t -of-r ou n dn ess does n ot
4 - INTAKE VALVE exceed 0.025 m m (0.001 in ch ), t h e cylin der bor e ca n
5 - EXHAUST VALVE be h on ed. If t h e cylin der bor e t a per or ou t - of-r ou n d
6 - VALVE SPRING con dit ion exceeds t h ese m a xim u m lim it s, t h e cylin der
m u st be bor ed a n d t h en h on ed t o a ccept a n over size
• Th e feed h oles for t h e cr a n ksh a ft m a in bea r in gs. pist on . A sligh t a m ou n t of t a per a lwa ys exist s in t h e
On ce t h e block h a s been com plet ely clea n ed, a pply cylin der bor e a ft er t h e en gin e h a s been in u se for a
Loct it e P ST pipe sea la n t wit h Teflon 592 t o t h e per iod of t im e.
t h r ea ds of t h e fr on t a n d r ea r oil ga lley plu gs. Tigh t en
t h e plu gs t o 34 N·m (25 ft . lbs.) t or qu e.
CAM SH AFT & BEARI N GS
INSPECTION
(1) It is m a n da t or y t o u se a dia l bor e ga u ge t o DESCRIPTION
m ea su r e ea ch cylin der bor e dia m et er (F ig. 29). To Th e ca m sh a ft is m a de of gr a y ca st ir on wit h t welve
cor r ect ly select t h e pr oper size pist on , a cylin der bor e m a ch in ed lobes a n d fou r bea r in g jou r n a ls (F ig. 30).
ga u ge, ca pa ble of r ea din g in 0.003 m m (.0001 in .) Wh en t h e ca m sh a ft r ot a t es t h e lobes a ct u a t e t h e t a p-
INCRE ME NTS is r equ ir ed. If a bor e ga u ge is n ot pet s a n d pu sh r ods, for cin g u pwa r d on t h e r ocker
a va ila ble, do n ot u se a n in side m icr om et er. a r m s wh ich a pplies down wa r d for ce on t h e va lves.
(2) Mea su r e t h e in side dia m et er of t h e cylin der
bor e a t t h r ee levels below t op of bor e. St a r t per pen - REMOVAL - CAMSHAFT BEARINGS
dicu la r (a cr oss or a t 90 degr ees) t o t h e a xis of t h e Th e ca m sh a ft r ot a t es wit h in fou r st eel-sh elled,
cr a n ksh a ft a n d t h en t a ke t wo a ddit ion a l r ea din g. ba bbit t -lin ed bea r in gs t h a t a r e pr essed in t o t h e cyl-
(3) Mea su r e t h e cylin der bor e dia m et er cr osswise in der block a n d t h en lin e r ea m ed. Th e ca m sh a ft
t o t h e cylin der block n ea r t h e t op of t h e bor e. Repea t bea r in g bor es a n d bea r in g dia m et er s a r e n ot t h e
t h e m ea su r em en t n ea r t h e m iddle of t h e bor e, t h en sa m e size. Th ey a r e st epped down in 0.254 m m
r epea t t h e m ea su r em en t n ea r t h e bot t om of t h e bor e. (0.010 in ch ) in cr em en t s fr om t h e fr on t bea r in g (la r g-
(4) Det er m in e t a per by su bt r a ct in g t h e sm a ller est ) t o t h e r ea r bea r in g (sm a llest ). Th is per m it s ea s-
dia m et er fr om t h e la r ger dia m et er. ier r em ova l a n d in st a lla t ion of t h e ca m sh a ft . Th e
(5) Rot a t e m ea su r in g device 90° a n d r epea t st eps ca m sh a ft bea r in gs a r e pr essu r e lu br ica t ed. Ca m sh a ft
a bove. en d pla y is m a in t a in ed by t h e t h r u st pla t e.
(6) Det er m in e ou t -of-r ou n dn ess by com pa r in g t h e
differ en ce bet ween ea ch m ea su r em en t .
WJ ENGINE - 4.0L 9 - 31
CAM SH AFT & BEARI N GS (Cont inue d)
(5) Rem ove t h e r ocker a r m s, br idges a n d pivot s
(Refer t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R
ARM / ADJ USTE R ASSY - RE MOVAL).
(6) Rem ove t h e pu sh r ods.
(7) Rem ove t h e en gin e cylin der h ea d a n d ga sket
(Refer t o 9 - E NGINE /CYLINDE R H E AD - RE MOV-
AL).
(8) Rem ove t h e h ydr a u lic va lve t a ppet s fr om t h e
en gin e cylin der block (Refer t o 9 - E NGINE /E NGINE
BLOCK/H YDRAULIC LIF TE RS (CAM IN BLOCK) -
RE MOVAL).
(9) Rem ove t h e vibr a t ion da m per (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL).
(10) Rem ove t h e t im in g ca se cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - RE MOVAL).
(11) Rot a t e t h e cr a n ksh a ft u n t il t h e cr a n ksh a ft
spr ocket t im in g m a r k is a lign ed on cen t er lin e wit h
t h e ca m sh a ft spr ocket t im in g m a r k (F ig. 32).
(12) Rem ove t h e t im in g ch a in a n d spr ocket s (Refer
t o 9 - E NGINE /VALVE TIMING/TIMING BE LT/
Fig. 30 Camshaft—Typical CH AIN AND SP ROCKE TS - RE MOVAL).
1 - CAMSHAFT (13) Rem ove t h e fr on t bu m per a n d/or gr ille, a s
2 - LOBES r equ ir ed.
3 - BEARING JOURNAL (14) Rem ove t h e t wo t h r u st pla t e r et a in in g scr ews,
t h r u st pla t e a n d ca m sh a ft (F ig. 31).
(1) Rem ove t h e ca m sh a ft (Refer t o 9 - E NGINE /
E NGINE BLOCK/CAMSH AF T & BE ARINGS (IN
BLOCK) - RE MOVAL).
NOTE: It is not advisable to attempt to replace cam-

shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Usin g Specia l t ool 8544 Ca m sh a ft Bu sh in g

Rem over In st a ller, r em ove t h e ca m sh a ft bea r in gs.
REMOVAL - CAMSHAFT
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) Discon n ect n ega t ive ca ble fr om ba t t er y.

(2) Dr a in t h e coolin g syst em (Refer t o 7 - COOL-
ING - STANDARD P ROCE DURE ).
(3) Rem ove t h e r a dia t or (Refer t o 7 - COOLING/ Fig. 31 Camshaft Removal
E NGINE /RADIATOR - RE MOVAL) a n d con den ser 1 - CAMSHAFT
(Refer t o 24 - H E ATING & AIR CONDITIONING/ 2 - CRANKSHAFT
P LUMBING/A/C CONDE NSE R - RE MOVAL), if
equ ipped wit h A/C.
(4) Rem ove t h e en gin e cylin der h ea d cover (Refer INSPECTION - CAMSHAFT BEARINGS
t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R (1) In spect t h e bea r in g jou r n a ls for u n even wea r
H E AD COVE R(S) - RE MOVAL). pa t t er n or fin ish .
9 - 32 ENGINE - 4.0L WJ
(2) Ca r efu lly in st a ll t h e ca m sh a ft t o pr even t da m -
a ge t o t h e ca m sh a ft bea r in gs.
(3) P osit ion t h r u st pla t e a n d in st a ll r et a in in g
scr ews. Tigh t en scr ews t o 24 N·m (18 ft . lbs.).
(4) Lu br ica t e t h e ca m sh a ft wit h Mopa r ! en gin e oil
su pplem en t , or equ iva len t .
(5) In st a ll t h e ca m sh a ft spr ocket , cr a n ksh a ft
spr ocket a n d t im in g ch a in (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT/CH AIN AND
SP ROCKE TS - INSTALLATION).
(6) Tigh t en t h e ca m sh a ft spr ocket bolt a n d wa sh er
t o 68 N·m (50 ft . lbs.).
(7) To ver ify cor r ect in st a lla t ion of t h e t im in g
ch a in , t u r n t h e cr a n ksh a ft t wo fu ll r evolu t ion s t h en
posit ion t h e ca m sh a ft spr ocket t im in g m a r k a s sh own
in (F ig. 33).
Fig. 32 Crankshaft / Camshaft Sprocket Timing Mark

Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
(2) In spect t h e bea r in gs for wea r.
INSPECTION - CAMSHAFT
(1) In spect t h e ca m lobes for wea r.
(2) In spect t h e ca m sh a ft posit ion sen sor dr ive gea r
for wea r.
(3) If t h e ca m sh a ft a ppea r s t o h a ve been r u bbin g
a ga in st t h e t h r u st wa sh er, exa m in e t h e oil pr essu r e
r elief h oles in t h e r ea r ca m jou r n a l. Th e oil pr essu r e
r elief h oles m u st be fr ee of debr is.
Fig. 33 Crankshaft / Camshaft Chain Drive
INSTALLATION - CAMSHAFT BEARINGS Installation—Typical
CAUTION: Make sure outside diameter of number 1 2 - TIMING MARKS
bearing is clean. Make sure that the bearing is 3 - CRANKSHAFT SPROCKET
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear- (8) In st a ll t h e t im in g ca se cover wit h a r epla ce-
ing bore. Failure to do so will cause inadequate oil m en t oil sea l (F ig. 34). (Refer t o 9 - E NGINE /VALVE
supply for the sprockets and timing chain. TIMING/TIMING BE LT / CH AIN COVE R(S) -
INSTALLATION).
(1) Usin g r ecom m en ded specia l t ool 8544 Ca m -
(9) In st a ll t h e vibr a t ion da m per (F ig. 34) (Refer t o
sh a ft Bea r in g Rem over /In st a ller, in st a ll n ew ca m -
9 - E NGINE /E NGINE BLOCK/VIBRATION
sh a ft bea r in gs.
DAMP E R - INSTALLATION).
(10) In st a ll t h e h ydr a u lic va lve t a ppet s (Refer t o 9
INSTALLATION - CAMSHAFT - E NGINE /E NGINE BLOCK/H YDRAULIC LIF TE RS
(1) Lu br ica t e t h e ca m sh a ft wit h Mopa r ! E n gin e
(CAM IN BLOCK) - INSTALLATION).
Oil Su pplem en t , or equ iva len t .
(11) In st a ll t h e cylin der h ea d ga sket wit h t h e
n u m ber s fa cin g u p.
WJ ENGINE - 4.0L 9 - 33
CON N ECT I N G ROD BEARI N GS

STANDARD PROCEDURES - FITTING
CONNECTING ROD BEARINGS
In spect t h e con n ect in g r od bea r in gs for scor in g a n d
ben t a lign m en t t a bs (F ig. 35) (F ig. 36). Ch eck t h e
bea r in gs for n or m a l wea r pa t t er n s, scor in g, gr oovin g,
fa t igu e a n d pit t in g (F ig. 37). Repla ce a n y bea r in g
t h a t sh ows a bn or m a l wea r.
In spect t h e con n ect in g r od jou r n a ls for sign s of
scor in g, n icks a n d bu r r s.
Fig. 34 Timing Case Cover Components

1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
(12) In st a ll t h e cylin der h ea d (Refer t o 9 -

E NGINE /CYLINDE R H E AD - INSTALLATION).
(13) In st a ll t h e pu sh r ods.
(14) In st a ll t h e r ocker a r m s a n d pivot a n d br idge
a ssem blies (Refer t o 9 - E NGINE /CYLINDE R H E AD/
ROCKE R ARM / ADJ USTE R ASSY - INSTALLA-
TION).
(15) In st a ll t h e en gin e cylin der h ea d cover (Refer
t o 9 - E NGINE /CYLINDE R H E AD/CYLINDE R Fig. 35 Connecting Rod Bearing Inspection
H E AD COVE R(S) - INSTALLATION). 1 - UPPER BEARING HALF
(16) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 - 2 - MATING EDGES
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - 3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
INSTALLATION). 4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
5 - LOWER BEARING HALF
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with
Mopar" Engine Oil Supplement, or equivalent. The
Mopar" Engine Oil Supplement, or equivalent must
remain with the engine oil for at least 1609 km
(1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(17) In st a ll t h e r a dia t or (Refer t o 7 - COOLING/

E NGINE /RADIATOR - INSTALLATION).
(18) Ch eck t h e ign it ion t im in g a n d a dju st a s n ec-
essa r y.
(19) In st a ll t h e gr ille a n d bu m per, if r em oved.
(20) Con n ect n ega t ive ca ble t o ba t t er y.
Fig. 36 Locking Tab Inspection

1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
9 - 34 ENGINE - 4.0L WJ
CON N ECT I N G ROD BEARI N GS (Cont inue d)
t or qu e. DO NOT r ot a t e cr a n ksh a ft . P la st iga ge will
sm ea r, r esu lt in g in in a ccu r a t e in dica t ion .
(7) Rem ove t h e bea r in g ca p a n d det er m in e a m ou n t
of bea r in g-t o- jou r n a l clea r a n ce by m ea su r in g t h e
widt h of com pr essed P la st iga ge (F ig. 39). P la s tig a g e
s h o u ld in d ic a te th e s a m e c le a ra n c e a c ro s s th e
e n tire w id th o f th e in s e rt. If th e c le a ra n c e v a r-
ie s , it m a y be c a u s e d by e ith e r a ta p e re d jo u r-
n a l, be n t c o n n e c tin g ro d o r fo re ig n m a te ria l
Fig. 37 Scoring Caused by Insufficient Lubrication tra p p e d be tw e e n th e in s e rt a n d c a p o r ro d .
or Damaged Crankshaft Journal
Misa lign ed or ben t con n ect in g r ods ca n ca u se
a bn or m a l wea r on pist on s, pist on r in gs, cylin der
wa lls, con n ect in g r od bea r in gs a n d cr a n ksh a ft con -
n ect in g r od jou r n a ls. If wea r pa t t er n s or da m a ge t o
a n y of t h ese com pon en t s in dica t e t h e pr oba bilit y of a
m isa lign ed con n ect in g r od, in spect it for cor r ect r od
a lign m en t . Repla ce m isa lign ed, ben t or t wist ed con -
n ect in g r ods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe t h e oil fr om t h e con n ect in g r od jou r n a l.
(2) Use sh or t r u bber h ose sect ion s over r od bolt s
du r in g in st a lla t ion .
(3) Lu br ica t e t h e u pper bea r in g in ser t a n d in st a ll
in con n ect in g r od.
(4) Use pist on r in g com pr essor t o in st a ll t h e r od Fig. 39 Measuring Bearing Clearance with
a n d pist on a ssem blies. Th e oil squ ir t h oles in t h e Plastigage
r ods m u st fa ce t h e ca m sh a ft . Th e a r r ow on t h e pist on 1 - PLASTIGAGE SCALE
cr own sh ou ld poin t t o t h e fr on t of t h e en gin e (F ig. 2 - COMPRESSED PLASTIGAGE
38). Ver ify t h a t t h e oil squ ir t h oles in t h e r ods fa ce
t h e ca m sh a ft a n d t h a t t h e a r r ows on t h e pist on s fa ce (8) If t h e cor r ect clea r a n ce is in dica t ed, r epla ce-
t h e fr on t of t h e en gin e. m en t of t h e bea r in g in ser t s is n ot n ecessa r y. Rem ove
t h e P la st iga ge fr om cr a n ksh a ft jou r n a l a n d bea r in g
in ser t . P r oceed wit h in st a lla t ion .
(9) If bea r in g-t o-jou r n a l clea r a n ce exceeds t h e
specifica t ion , in st a ll a pa ir of 0.0254 m m (0.001 in ch )
u n der size bea r in g in ser t s. All t h e odd size in ser t s
m u st be on t h e bot t om . Th e sizes of t h e ser vice
r epla cem en t bea r in g in ser t s a r e st a m ped on t h e
ba cks of t h e in ser t s. Mea su r e t h e clea r a n ce a s
descr ibed in t h e pr eviou s st eps.
(10) Th e clea r a n ce is m ea su r ed wit h a pa ir of
0.0254 m m (0.001 in ch ) u n der size bea r in g in ser t s
in st a lled. Th is will det er m in e if t wo 0.0254 m m
(0.001 in ch ) u n der size in ser t s or a n ot h er com bin a t ion
is n eeded t o pr ovide t h e cor r ect clea r a n ce. Refer t o
Fig. 38 Rod and Piston Assembly Installation CONNE CTING ROD BE ARING F ITTING CH ART .
(5) In st a ll t h e lower bea r in g in ser t in t h e bea r in g
ca p. Th e lower in ser t m u st be dr y. P la ce st r ip of P la s-
t iga ge a cr oss fu ll widt h of t h e lower in ser t a t t h e cen -
t er of bea r in g ca p. P la st iga ge m u st n ot cr u m ble in
u se. If br it t le, obt a in fr esh st ock.
(6) In st a ll bea r in g ca p a n d con n ect in g r od on t h e
jou r n a l a n d t igh t en n u t s t o 45 N·m (33 ft . lbs.)
WJ ENGINE - 4.0L 9 - 35
CON N ECT I N G ROD BEARI N G FI T T I N G CH ART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT

Color Code Diameter Upper Insert Size Lower Insert Size
53.2257 - 53.2079 mm
Yellow Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
53.2079 - 53.1901 mm
(2.0948 - 2.0941 in.) Blue - Undersize
Orange Yellow - Standard
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
53.1901 - 53.1724 mm
Blue (2.0941 - 2.0934 in.) Blue - Undersize Blue - Undersize

0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
52.9717 - 52.9539 mm
(2.0855 - 2.0848 in.) Red - Undersize Red - Undersize
Red
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) F OR EXAMP LE: If t h e in it ia l clea r a n ce wa s

0.0762 m m (0.003 in ch ), 0.025 m m (0.001 in ch )
u n der size in ser t s wou ld r edu ce t h e clea r a n ce by
0.025 m m (0.001 in ch ). Th e clea r a n ce wou ld be 0.002
in ch a n d wit h in specifica t ion . A 0.051 m m (0.002
in ch ) u n der size in ser t wou ld r edu ce t h e in it ia l clea r-
a n ce a n a ddit ion a l 0.013 m m (0.0005 in ch ). Th e
clea r a n ce wou ld t h en be 0.038 m m (0.0015 in ch ).
(12) Repea t t h e P la st iga ge m ea su r em en t t o ver ify
you r bea r in g select ion pr ior t o fin a l a ssem bly.
(13) On ce you h a ve select ed t h e pr oper in ser t ,
in st a ll t h e in ser t a n d ca p. Tigh t en t h e con n ect in g r od
bolt s t o 45 N·m (33 ft . lbs.) t or qu e.
SIDE CLEARANCE MEASUREMENT

Slide sn u g-fit t in g feeler ga u ge bet ween t h e con -
n ect in g r od a n d cr a n ksh a ft jou r n a l fla n ge (F ig. 40). Fig. 40 Checking Connecting Rod Side Clearance -
(Refer t o 9 - E NGINE - SP E CIF ICATIONS). Repla ce Typical
t h e con n ect in g r od if t h e side clea r a n ce is n ot wit h in
specifica t ion .
9 - 36 ENGINE - 4.0L WJ
CRAN K SH AFT Th e m a in bea r in g jou r n a l size (dia m et er ) is iden t i-

fied by a color-coded pa in t m a r k (F ig. 42)on t h e a dja -
cen t ch eek or cou n t er weigh t t owa r ds t h e r ea r of t h e
DESCRIPTION
cr a n ksh a ft (fla n ge en d). Th e r ea r m a in jou r n a l, is
Th e cr a n ksh a ft is con st r u ct ed of n odu la r ca st ir on .
iden t ified by a color-coded pa in t m a r k on t h e cr a n k-
Th e cr a n ksh a ft is a cr ossh a ped fou r t h r ow design
sh a ft r ea r fla n ge.
wit h eigh t cou n t er weigh t s for ba la n cin g pu r poses.
Wh en r equ ir ed, u pper a n d lower bea r in g in ser t s of
Th e cr a n ksh a ft is su ppor t ed by seven select m a in
differ en t sizes m a y be u sed a s a pa ir. A st a n da r d size
bea r in gs wit h t h e n u m ber t h r ee ser vin g a s t h e t h r u st
in ser t is som et im es u sed in com bin a t ion wit h a 0.025
wa sh er loca t ion . Th e m a in jou r n a ls of t h e cr a n ksh a ft
m m (0.001 in ch ) u n der size in ser t t o r edu ce t h e clea r-
a r e cr oss dr illed t o im pr ove r od bea r in g lu br ica t ion .
a n ce by 0.013 m m (0.0005 in ch ). N e v e r u s e a p a ir
Th e select fit m a in bea r in g m a r kin gs a r e loca t ed on
o f be a rin g in s e rts w ith g re a te r th a n a 0.025 m m
t h e cr a n ksh a ft cou n t er weigh t s. Th e cr a n ksh a ft r ea r
(0.001 in c h ) d iffe re n c e in s ize . Re fe r to th e
oil sea l is a t wo piece design . Th e fr on t oil sea l is a
B e a rin g In s e rt P a ir Ch a rt.
on e piece design r et a in ed in t h e t im in g ch a in cover
(F ig. 41). NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
On ce t h e bea r in gs h a ve been pr oper ly fit t ed, pr o-

ceed t o .
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT

INSTALLED)
Wh en u sin g P la st iga ge, ch eck on ly on e bea r in g
clea r a n ce a t a t im e.
In st a ll t h e gr ooved m a in bea r in gs in t o t h e cylin der
block a n d t h e n on -gr ooved bea r in gs in t o t h e bea r in g
ca ps.
Fig. 41 Crankshaft with Select Fit Marking Location In st a ll t h e cr a n ksh a ft in t o t h e u pper bea r in gs dr y.
1 - 1/4” LETTERS P la ce a st r ip of P la st iga ge a cr oss fu ll widt h of t h e
2 - (ROD) cr a n ksh a ft jou r n a l t o be ch ecked.
3 - (MAIN) In st a ll t h e bea r in g ca p a n d t igh t en t h e bolt s t o 108
CRAN K SH AFT M AI N NOTE: DO NOT rotate the crankshaft. This will

cause the Plastigage to shift, resulting in an inaccu-
BEARI N GS rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS Rem ove t h e bea r in g ca p. Det er m in e t h e a m ou n t of
clea r a n ce by m ea su r in g t h e widt h of t h e com pr essed
FITTING BEARINGS (CRANKSHAFT INSTALLED) P la st iga ge wit h t h e sca le on t h e P la st iga ge en velope
Th e m a in bea r in g ca ps, n u m ber ed (fr on t t o r ea r ) (F ig. 43). (Refer t o 9 - E NGINE - SP E CIF ICATIONS)
fr om 1 t h r ou gh 7 h a ve a n a r r ow t o in dica t e t h e for- for t h e pr oper clea r a n ce.
wa r d posit ion . Th e u pper m a in bea r in g in ser t s a r e P la st iga ge sh ou ld in dica t e t h e sa m e clea r a n ce
gr ooved t o pr ovide oil ch a n n els wh ile t h e lower a cr oss t h e en t ir e widt h of t h e in ser t . If clea r a n ce va r-
in ser t s a r e sm oot h . ies, it m a y in dica t e a t a per ed jou r n a l or for eign
E a ch bea r in g in ser t pa ir is select ively fit t ed t o it s m a t er ia l t r a pped beh in d t h e in ser t .
r espect ive jou r n a l t o obt a in t h e specified oper a t in g If t h e specified clea r a n ce is in dica t ed a n d t h er e a r e
clea r a n ce. In pr odu ct ion , t h e select fit is obt a in ed by n o a bn or m a l wea r pa t t er n s, r epla cem en t of t h e bea r-
u sin g va r iou s-sized color-coded bea r in g in ser t pa ir s in g in ser t s is n ot n ecessa r y. Rem ove t h e P la st iga ge
a s list ed in t h e Ma in Bea r in g F it t in g Ch a r t . Th e fr om t h e cr a n ksh a ft jou r n a l a n d bea r in g in ser t . P r o-
bea r in g color code a ppea r s on t h e edge of t h e in ser t . ceed t o (Refer t o 9 - E NGINE /E NGINE BLOCK/
Th e s ize is n o t s ta m p e d o n be a rin g in s e rts u s e d CRANKSH AF T MAIN BE ARINGS -
fo r e n g in e p ro d u c tio n . INSTALLATION).
WJ ENGINE - 4.0L 9 - 37
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
Fig. 42 Crankshaft Journal Size Paint I.D. Location

1 - NO. 7 MAIN JOURNAL SIZE PAINT MARK 3 - NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
2 - NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK 4 - NO. 1 MAIN JOURNAL SIZE PAINT MARK
wou ld r edu ce t h e clea r a n ce by 0.0254 m m (0.001

in ch ). Th e clea r a n ce wou ld t h en be 0.0508 m m (0.002
in ch ) a n d wit h in t h e specifica t ion . A 0.051 m m (0.002
in ch ) u n der size bea r in g in ser t a n d a 0.0254 m m
(0.001 in ch ) u n der size in ser t wou ld r edu ce t h e or igi-
n a l clea r a n ce a n a ddit ion a l 0.0127 m m (0.0005 in ch ).
Th e clea r a n ce wou ld t h en be 0.0381 m m (0.0015
in ch ).
CAUTION: Never use a pair of inserts that differ

more than one bearing size as a pair.
F OR EXAMP LE: DO NOT u se a st a n da r d size

u pper in ser t a n d a 0.051 m m (0.002 in ch ) u n der size
lower in ser t .
If t h e clea r a n ce exceeds specifica t ion u sin g a pa ir
Fig. 43 Measuring Bearing Clearance with of 0.051 m m (0.002 in ch ) u n der size bea r in g in ser t s,
Plastigage m ea su r e cr a n ksh a ft jou r n a l dia m et er wit h a
m icr om et er. If t h e jou r n a l dia m et er is cor r ect , t h e
1 - PLASTIGAGE SCALE
cr a n ksh a ft bor e in t h e cylin der block m a y be m is-
2 - COMPRESSED PLASTIGAGE
a lign ed, wh ich r equ ir es cylin der block r epla cem en t or
m a ch in in g t o t r u e bor e.
If t h e clea r a n ce exceeds specifica t ion , in st a ll a pa ir Repla ce t h e cr a n ksh a ft or gr in d t o a ccept t h e
of 0.025 m m (0.001 in ch ) u n der size bea r in g in ser t s a ppr opr ia t e u n der size bea r in g in ser t s if:
a n d m ea su r e t h e clea r a n ce a s descr ibed in t h e pr evi- • J ou r n a l dia m et er s 1 t h r ou gh 6 a r e less t h a n
ou s st eps. 63.4517 m m (2.4981 in ch es)
Th e clea r a n ce in dica t e wit h t h e 0.025 m m (0.001 • J ou r n a l 7 dia m et er is less t h a n 63.4365 m m
in ch ) u n der size in ser t pa ir in st a lled will det er m in e if (2.4975 in ch es).
t h is in ser t size or som e ot h er com bin a t ion will pr o- On ce t h e pr oper clea r a n ces h a ve been obt a in ed,
vide t h e specified clea r a n ce. F OR EXAMP LE: If t h e pr oceed t o (Refer t o 9 - E NGINE /E NGINE BLOCK/
clea r a n ce wa s 0.0762 m m (0.003 in ch ) or igin a lly, a CRANKSH AF T MAIN BE ARINGS - INSTALLA-
pa ir of 0.0254 m m (0.001 in ch ) u n der size in ser t s TION).
9 - 38 ENGINE - 4.0L WJ
JOURNAL DIAMETER (CRANKSHAFT REMOVED) Corresponding
Rem ove t h e cr a n ksh a ft fr om t h e cylin der block. Crankshaft Journals
Crankshaft Bearing
Clea n t h e oil off t h e m a in bea r in g jou r n a l. #1-6
Insert
Det er m in e t h e m a xim u m dia m et er of t h e jou r n a l
Color Upper Lower
wit h a m icr om et er. Mea su r e a t t wo loca t ion s 90° Diameter
Code Insert Size Insert Size
a pa r t a t ea ch en d of t h e jou r n a l.
Th e m a xim u m a llowa ble t a per a n d ou t of r ou n d is 63.4644 -
0.013 m m (0.0005 in ch ). Com pa r e t h e m ea su r ed 63.4517
dia m et er wit h t h e jou r n a l dia m et er specifica t ion mm
MAIN BE ARING F ITTING CH ART . Select in ser t s (2.4986 - Blue - Green -
r equ ir ed t o obt a in t h e specified bea r in g-t o-jou r n a l 2.4981 in.) Undersize Undersize
Green
clea r a n ce. 0.025 mm 0.051 mm
0.0381 mm (0.001 in.) (0.002 in.)
In st a ll t h e cr a n ksh a ft in t o t h e cylin der block. (0.0015
in.)
M AI N BEARI N G FI T T I N G CH ART
Undersize
Corresponding 63.2485 -
Crankshaft Journals 63.2358
Crankshaft Bearing
#1-6 mm
Insert Red - Red -
Color Upper Lower (2.4901 - Undersize Undersize
Diameter Red 2.4896 in.)
Code Insert Size Insert Size 0.254 mm 0.254 mm
63.5025 0.254 mm (0.010 in.) (0.010 in.)
-63.4898 (0.010 in.)
mm Yellow - Yellow -
Yellow Undersize
Standard Standard
(2.5001 -
2.4996 in.)
Crankshaft Journal #7 Corresponding Bearing
63.4898 - Only Insert
63.4771
Color Upper Lower
mm Diameter
(2.4996 - Blue -
Yellow - Undersize 63.4873 -
Orange 2.4991 in.)
Standard 0.025 mm 63.4746
0.0127 mm mm Yellow - Yellow -
(0.001 in.) Yellow
(0.0005 Standard Standard
(2.4995 -
in.) 2.4990 in.)
Undersize 63.4746 -
63.4771 - 63.4619
63.4644 mm
mm (2.4990 - Blue -
Blue - Blue -
(2.4991 - 2.4985 in.) Yellow - Undersize
Undersize Undersize Orange
Blue 2.4986 in.) Standard 0.025 mm
0.025 mm 0.025 mm 0.0127 mm (0.001 in.)
0.0254 mm (0.001 in.) (0.001 in.) (0.0005
(0.001 in.) in.)
Undersize Undersize
63.4619 -
63.4492
mm
Blue - Blue -
(2.4985 - Undersize Undersize
Blue 2.4980 in.) 0.025 mm 0.025 mm
0.0254 mm (0.001 in.) (0.001 in.)
(0.001 in.)
Undersize
WJ ENGINE - 4.0L 9 - 39
Crankshaft Journal #7 Corresponding Bearing

Only Insert
Color Upper Lower
Diameter
63.4492 -
63.4365
mm
(2.4980 - Blue - Green -
2.4975 in.) Undersize Undersize
Green
0.025 mm 0.051 mm
0.0381 mm (0.001 in.) (0.002 in.)
(0.0015
in.)
Undersize
63.2333 -
63.2206
mm
Red - Red -
(2.4895 - Undersize Undersize
Red 2.4890 in.) 0.254 mm 0.254 mm Fig. 44 Main Bearing Caps and Brace.
0.254 mm (0.010 in.) (0.010 in.)
1 - BLOCK
(0.010 in.) 2 - MAIN BEARING CAP BRACE
Undersize
REMOVAL
(2) Rem ove t h e spa r k plu gs (Refer t o 8 - E LE C-
TRICAL/IGNITION CONTROL/SPARK P LUG -
RE MOVAL).
(3) Ra ise t h e veh icle.
(4) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - RE MOVAL) a n d oil pu m p
(Refer t o 9 - E NGINE /LUBRICATION/OIL P UMP -
RE MOVAL).
(5) Rem ove m a in bea r in g ca p br a ce (F ig. 44).
(6) Rem ove on ly on e m a in bea r in g ca p a n d lower
in ser t a t a t im e (F ig. 45).
(7) Rem ove t h e lower in ser t fr om t h e bea r in g ca p.
(8) Rem ove t h e u pper in ser t by LOOSE NING (DO
NOT RE MOVE ) a ll of t h e ot h er bea r in g ca ps. Now
in ser t a sm a ll cot t er pin t ool in t h e cr a n ksh a ft jou r-
n a l oil h ole. Ben d t h e cot t er pin a s illu st r a t ed t o fa b-
r ica t e t h e t ool (F ig. 46). Wit h t h e cot t er pin t ool in
pla ce, r ot a t e t h e cr a n ksh a ft so t h a t t h e u pper bea r-
in g in ser t will r ot a t e in t h e dir ect ion of it s lockin g Fig. 45 Removing Main Bearing Caps and Lower
t a b. Beca u se t h er e is n o h ole in t h e No.3 m a in jou r- Inserts
n a l, u se a t on gu e depr essor or sim ila r soft -fa ced t ool 1 - CONNECTING ROD JOURNAL
t o r em ove t h e bea r in g in ser t (F ig. 46). Aft er m ovin g 2 - MAIN BEARING CAPS
t h e in ser t a ppr oxim a t ely 25 m m (1 in ch ), it ca n be
r em oved by a pplyin g pr essu r e u n der t h e t a b.
(9) Usin g t h e sa m e pr ocedu r e descr ibed a bove, INSPECTION
r em ove t h e r em a in in g bea r in g in ser t s on e a t a t im e Wipe t h e in ser t s clea n a n d in spect for a bn or m a l
for in spect ion . wea r pa t t er n s a n d for m et a l or ot h er for eign m a t er ia l
im bedded in t h e lin in g. Nor m a l m a in bea r in g in ser t
9 - 40 ENGINE - 4.0L WJ
In spect t h e ba ck of t h e in ser t s for fr a ct u r es, scr a p-
in gs or ir r egu la r wea r pa t t er n s.
In spect t h e u pper in ser t lockin g t a bs for da m a ge.
Repla ce a ll da m a ged or wor n bea r in g in ser t s.
INSTALLATION
(1) Lu br ica t e t h e bea r in g su r fa ce of ea ch in ser t
wit h en gin e oil.
(2) Loosen a ll t h e m a in bea r in g ca ps. In st a ll t h e
m a in bea r in g u pper in ser t s.
(3) In st a ll t h e lower bea r in g in ser t s in t o t h e m a in
bea r in g ca ps.
(4) On t h e r ea r m a in ca p, a pply Mopa r ! Ga sket
Ma ker sea ler on bot h sides of cylin der block a s
sh own in (F ig. 48). Th e da b of sea ler sh ou ld be 3 m m
(0.125 in .) in dia m et er.
(5) Apply Mopa r ! Ga sket Ma ker on t h e r ea r bea r-
in g ca p. Th e bea d sh ou ld be 2.3 m m (0.09 in .) in
dia m et er. DO NOT a pply sea ler t o t h e lip of t h e sea l.
Fig. 46 Removing Upper Inserts

1 - COTTER PIN
2 - BEARING INSERT
3 - TONGUE DEPRESSOR
wea r pa t t er n s a r e illu st r a t ed (F ig. 47). In gen er a l t h e

lower bea r in g h a lf will h a ve a h ea ver wea r pa t t er n .
Fig. 48 Location of Sealer

1 - DOWEL
2 - SEALER LOCATIONS
3 - CYLINDER BLOCK
4 - HALFWAY BETWEEN
Fig. 47 Main Bearing Wear Patterns
5 - REAR FACE OF CYLINDER BLOCK
1 - UPPER INSERT 6 - 3mm (0.125 in.)
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT (6) In st a ll t h e m a in bea r in g ca p(s) a n d lower
in ser t (s).
(7) Tigh t en t h e bolt s of ca ps 1, 2, 4, 5, 6, a n d 7 t o
NOTE: If any of the crankshaft journals are scored,
54 N·m (40 ft . lbs.) t or qu e. Now t igh t en t h ese bolt s t o
remove the engine for crankshaft repair.
95 N·m (70 ft . lbs.) t or qu e. F in a lly, t igh t en t h ese
bolt s t o 108 N·m (80 ft . lbs.) t or qu e.
WJ ENGINE - 4.0L 9 - 41
(8) P u sh t h e cr a n ksh a ft for wa r d a n d ba ckwa r d. (13) In st a ll oil pu m p a ssy. a n d t igh t en a t t a ch in g
Loa d t h e cr a n ksh a ft fr on t or r ea r a n d t igh t en ca p bolt s t o 23 N·m (17 ft . lbs.)
bolt No.3 t o 54 N·m (40 ft . lbs.) t or qu e. Th en t igh t en (14) In st a ll t h e oil pa n (Refer t o 9 - E NGINE /LU-
t o 95 N·m (70 ft . lbs.) t or qu e a n d fin a lly t igh t en t o BRICATION/OIL PAN - INSTALLATION).
108 N·m (80 ft . lbs.) t or qu e. (15) In st a ll t h e dr a in plu g. Tigh t en t h e plu g t o 34
(9) Rot a t e t h e cr a n ksh a ft a ft er t igh t en in g ea ch N·m (25 ft . lbs.) t or qu e.
m a in bea r in g ca p t o en su r e t h e cr a n ksh a ft r ot a t es (16) Lower t h e veh icle.
fr eely. (17) In st a ll t h e spa r k plu gs. Tigh t en t h e plu gs t o
(10) Ch eck cr a n ksh a ft en d pla y. Cr a n ksh a ft en d 37 N·m (27 ft . lbs.) t or qu e.
pla y is con t r olled by t h e t h r u st bea r in g wh ich is (18) F ill t h e oil pa n wit h en gin e oil t o t h e fu ll
fla n ge a n d in st a lled a t t h e No.2 m a in bea r in g posi- m a r k on t h e dipst ick level.
t ion . (19) Con n ect n ega t ive ca ble t o ba t t er y.
(a ) At t a ch a m a gn et ic ba se dia l in dica t or t o t h e
cylin der block a t eit h er t h e fr on t or r ea r of t h e
en gin e. CRAN K SH AFT OI L SEAL -
(b) P osit ion t h e dia l in dica t or r od so t h a t it is FRON T
pa r a llel t o t h e cen t er lin e of t h e cr a n ksh a ft .
(c) P r y t h e cr a n ksh a ft for wa r d, posit ion t h e dia l REMOVAL
in dica t or t o zer o. Th is pr ocedu r e is don e wit h t h e t im in g ca se cover
(d) P r y t h e cr a n ksh a ft for wa r d a n d ba ckwa r d. in st a lled.
Not e t h e dia l in dica t or r ea din gs. E n d pla y is t h e (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
differ en ce bet ween t h e h igh a n d low m ea su r em en t s (2) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 -
(F ig. 49). Cor r ect en d pla y is 0.038-0.165 m m COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
(0.0015-0.0065 in ch ). Th e desir ed specifica t ion s a r e RE MOVAL).
0.051-0.064 m m (0.002-0.0025 in ch ). (3) Rem ove t h e vibr a t ion da m per (Refer t o 9 -
(e) If en d pla y is n ot wit h in specifica t ion , in spect E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
cr a n ksh a ft t h r u st fa ces for wea r. If n o wea r is RE MOVAL).
a ppa r en t , r epla ce t h e t h r u st bea r in g a n d m ea su r e (4) Rem ove t h e r a dia t or sh r ou d.
en d pla y. If en d pla y is st ill n ot wit h in specifica - (5) Ca r efu lly r em ove t h e oil sea l. Ma ke su r e sea l
t ion , r epla ce t h e cr a n ksh a ft . bor e is clea n .
INSTALLATION
Th is pr ocedu r e is don e wit h t h e t im in g ca se cover
in st a lled.
(1) P osit ion t h e r epla cem en t oil sea l on Tim in g
Ca se Cover Align m en t a n d Sea l In st a lla t ion Tool
6139 wit h sea l open en d fa cin g in wa r d. Apply a ligh t
film of P er fect Sea l, or equ iva len t , on t h e ou t side
dia m et er of t h e sea l. Ligh t ly coa t t h e cr a n ksh a ft wit h
en gin e oil.
(2) P osit ion t h e t ool a n d sea l over t h e en d of t h e
cr a n ksh a ft a n d in ser t a dr a w scr ew t ool in t o Sea l
In st a lla t ion Tool 6139 (F ig. 50). Tigh t en t h e n u t
a ga in st t h e t ool u n t il it con t a ct s t h e cover.
(3) Rem ove t h e t ools. Apply a ligh t film of en gin e
oil on t h e vibr a t ion da m per h u b con t a ct su r fa ce of
t h e sea l.
Fig. 49 Crankshaft End Play Measurement (4) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
1 - DIAL INDICATOR a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
2 - CRANKSHAFT key. Wit h t h e key in ser t ed in t h e keywa y in t h e
cr a n ksh a ft , in st a ll t h e vibr a t ion da m per (Refer t o 9 -
(11) If t h e cr a n ksh a ft wa s r em oved, in st a ll t h e E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
cr a n ksh a ft in t o t h e cylin der block. INSTALLATION).
(12) In st a ll m a in bea r in g ca p br a ce t igh t en n u t s t o (5) In st a ll t h e ser pen t in e belt (Refer t o 7 - COOL-
47 N·m (35 ft . lbs.) t or qu e. ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
LATION).
9 - 42 ENGINE - 4.0L WJ
CRAN K SH AFT OI L SEAL - FRON T (Cont inue d)
(4) Ca r efu lly posit ion t h e u pper sea l in t o t h e
gr oove in t h e cylin der block. Th e lip of t h e sea l fa ces
t owa r d t h e fr on t of t h e en gin e.
(5) Apply Mopa r ! Ga sket Ma ker sea ler on bot h
sides of cylin der block a s sh own in (F ig. 51). Th e da b
of sea ler sh ou ld be 3 m m (0.125 in .) in dia m et er.
(6) Apply Mopa r ! Ga sket Ma ker on t h e r ea r bea r-
in g ca p (F ig. 51). Th e bea d sh ou ld be 2.3 m m (0.09
in .) in dia m et er. DO NOT a pply sea ler t o t h e lip of
t h e sea l.
(7) P osit ion t h e lower sea l in t o t h e bea r in g ca p
r ecess a n d sea t it fir m ly. Be su r e t h e sea l is flu sh
wit h t h e cylin der block pa n r a il.
(8) Coa t t h e ou t er cu r ved su r fa ce of t h e lower sea l
wit h soa p a n d t h e lip of t h e sea l wit h en gin e oil.
Fig. 50 Timing Case Cover Oil Seal Installation

1 - SEAL INSTALLATION TOOL
2 - DRAW SCREW TOOL
(6) In st a ll t h e r a dia t or sh r ou d.
CRAN K SH AFT OI L SEAL -

REAR
REMOVAL
Th e cr a n ksh a ft r ea r m a in bea r in g oil sea l con sist s
of t wo h a lf pieces of vit on wit h a sin gle lip t h a t effec-
t ively sea ls t h e r ea r of t h e cr a n ksh a ft . Repla ce t h e
u pper a n d lower sea l h a lves a s a u n it t o en su r e lea k-
fr ee oper a t ion .
(1) Rem ove t r a n sm ission in spect ion cover.
(2) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - RE MOVAL)
Fig. 51 Location of Sealer
(3) Rem ove m a in bea r in g ca p br a ce.
1 - DOWEL
(4) Rem ove r ea r m a in bea r in g ca p (No.7).
2 - SEALER LOCATIONS
(5) P u sh u pper sea l ou t of t h e gr oove. E n su r e t h a t
3 - CYLINDER BLOCK
t h e cr a n ksh a ft a n d sea l gr oove a r e n ot da m a ged. 4 - HALFWAY BETWEEN
(6) Rem ove lower h a lf of t h e sea l fr om t h e bea r in g 5 - REAR FACE OF CYLINDER BLOCK
ca p. 6 - 3mm (0.125 in.)
INSTALLATION (9) In st a ll t h e r ea r m a in bea r in g ca p. DO NOT

Th e cr a n ksh a ft r ea r m a in bea r in g oil sea l con sist s
st r ike t h e ca p m or e t h a n t wice for pr oper en ga ge-
of t wo h a lf pieces of vit on wit h a sin gle lip t h a t effec-
m en t .
t ively sea ls t h e r ea r of t h e cr a n ksh a ft . Repla ce t h e
(10) Tigh t en a ll m a in bea r in g bolt s t o 108 N·m (80
u pper a n d lower sea l h a lves a s a u n it t o en su r e lea k-
ft . lbs.) t or qu e.
fr ee oper a t ion .
(11) In st a ll t h e m a in bea r in g ca p br a ce. Tigh t en
(1) Wipe t h e sea l su r fa ce a r ea of t h e cr a n ksh a ft
n u t s t o 47 N·m (35 ft . lbs.).
u n t il it is clea n .
(12) In st a ll t h e oil pa n ga sket a n d oil pa n (Refer t o
(2) Apply a t h in coa t of en gin e oil.
9 - E NGINE /LUBRICATION/OIL PAN - INSTALLA-
(3) Coa t lip of t h e sea l wit h en gin e oil.
TION).
WJ ENGINE - 4.0L 9 - 43
CRAN K SH AFT OI L SEAL - REAR (Cont inue d)
(13) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t on cylin der block t o r ea r m a in bea r in g ca p cor-
n er s a n d cylin der block t o fr on t cover join t s (fou r
pla ces) (F ig. 52)
Fig. 53 HYDRAULIC VALVE TAPPET REMOVAL -

4.0L
1 - HYDRAULIC TAPPET REMOVAL TOOL
2 - CYLINDER BLOCK
Fig. 52 Oil Pan

Swin g t h e weigh t ed a r m of t h e h ydr a u lic va lve t a p-
1 - SEALER LOCATIONS pet t est er a wa y fr om t h e r a m of t h e Lea k-Down
Test er.
(14) In st a ll t r a n sm ission in spect ion cover. (1) P la ce a 7.925-7.950 m m (0.312-0.313 in ch )
dia m et er ba ll bea r in g on t h e plu n ger ca p of t h e t a p-
pet .
H Y DRAU LI C LI FT ERS (2) Lift t h e r a m a n d posit ion t h e t a ppet (wit h t h e
ba ll bea r in g) in side t h e t est er cu p.
DESCRIPTION (3) Lower t h e r a m , t h en a dju st t h e n ose of t h e r a m
Va lve la sh is con t r olled by h ydr a u lic t a ppet s u n t il it con t a ct s t h e ba ll bea r in g. DO NOT t igh t en
loca t ed in side t h e cylin der block, in t a ppet bor es t h e h ex n u t on t h e r a m .
a bove t h e ca m sh a ft . (4) F ill t h e t est er cu p wit h h ydr a u lic va lve t a ppet
t est oil u n t il t h e t a ppet is com plet ely su bm er ged.
REMOVAL (5) Swin g t h e weigh t ed a r m on t o t h e pu sh r od a n d
pu m p t h e t a ppet plu n ger u p a n d down t o r em ove a ir.
NOTE: Retain all the components in the same order Wh en t h e a ir bu bbles cea se, swin g t h e weigh t ed a r m
as removed. a wa y a n d a llow t h e plu n ger t o r ise t o t h e n or m a l
posit ion .
(1) Rem ove t h e en gin e cylin der h ea d(Refer t o 9 - (6) Adju st t h e n ose of t h e r a m t o a lign t h e poin t er
E NGINE /CYLINDE R H E AD - RE MOVAL) . wit h t h e SE T m a r k on t h e sca le of t h e t est er a n d
(2) Rem ove t h e pu sh r ods. t igh t en t h e h ex n u t .
(3) Rem ove t h e t a ppet s t h r ou gh t h e pu sh r od open - (7) Slowly swin g t h e weigh t ed a r m on t o t h e pu sh
in gs in t h e cylin der block wit h a H ydr a u lic Va lve r od.
Ta ppet Rem ova l/In st a lla t ion Tool (F ig. 53). (8) Rot a t e t h e cu p by t u r n in g t h e h a n dle a t t h e
ba se of t h e t est er clockwise on e r evolu t ion ever y 2
CLEANING secon ds.
Clea n ea ch t a ppet a ssem bly in clea n in g solven t t o (9) Obser ve t h e lea k-down t im e in t er va l fr om t h e
r em ove a ll va r n ish , gu m a n d slu dge deposit s. in st a n t t h e poin t er a lign s wit h t h e START m a r k on
t h e sca le u n t il t h e poin t er a lign s wit h t h e 0.125
INSPECTION m a r k. A n or m a lly fu n ct ion in g t a ppet will r equ ir e
In spect for in dica t ion s of scu ffin g on t h e side a n d 20-110 secon ds t o lea k-down . Disca r d t a ppet s wit h
ba se of ea ch t a ppet body. lea k-down t im e in t er va l n ot wit h in t h is specifica t ion .
In spect ea ch t a ppet ba se for con ca ve wea r wit h a
st r a igh t edge posit ion ed a cr oss t h e ba se. If t h e ba se is INSTALLATION
con ca ve, t h e cor r espon din g lobe on t h e ca m sh a ft is Ret a in a ll t h e com pon en t s in t h e sa m e or der a s
a lso wor n . Repla ce t h e ca m sh a ft a n d t a ppet s. r em oved.
Aft er clea n in g a n d in spect ion , t est ea ch t a ppet for It is n ot n ecessa r y t o ch a r ge t h e t a ppet s wit h
specified lea k-down r a t e t oler a n ce t o en su r e zer o-la sh en gin e oil. Th ey will ch a r ge t h em selves wit h in a ver y
oper a t ion (F ig. 54). sh or t per iod of en gin e oper a t ion .
9 - 44 ENGINE - 4.0L WJ
H Y DRAU LI C LI FT ERS (Cont inue d)
vide scu ff r esist a n ce. Th e con n ect in g r ods a r e m a de
of ca st ir on .
Fig. 54 Leak-Down Tester

1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP Fig. 55 Piston and Connecting Rod Assembly
5 - HANDLE
6 - PUSH ROD STANDARD PROCEDURE - PISTON FITTING
(1) To cor r ect ly select t h e pr oper size pist on , a cyl-
(1) Dip ea ch t a ppet in Mopa r ! E n gin e Oil Su pple- in der bor e ga u ge, ca pa ble of r ea din g in 0.003 m m (
m en t , or equ iva len t . .0001 in .) INCRE ME NTS is r equ ir ed. If a bor e ga u ge
(2) Use H ydr a u lic Va lve Ta ppet Rem ova l/In st a lla - is n ot a va ila ble, do n ot u se a n in side m icr om et er.
t ion Tool t o in st a ll ea ch t a ppet in t h e sa m e bor e fr om (2) Mea su r e t h e in side dia m et er of t h e cylin der
wh er e it wa s or igin a lly r em oved. bor e a t a poin t 49.5 m m (1-15/16 in ch es) below t op of
(3) In st a ll t h e cylin der h ea d (Refer t o 9 - E NGINE / bor e. St a r t per pen dicu la r (a cr oss or a t 90 degr ees) t o
CYLINDE R H E AD - INSTALLATION). t h e a xis of t h e cr a n ksh a ft a t poin t A a n d t h en t a ke
(4) In st a ll t h e pu sh r ods in t h eir or igin a l loca t ion s. a n a ddit ion a l bor e r ea din g 90 degr ees t o t h a t a t poin t
(5) In st a ll t h e r ocker a r m s a n d br idge a n d pivot B (F ig. 57).
a ssem blies a t t h eir or igin a l loca t ion s. Loosely in st a ll (3) Th e coa t ed pist on s will be ser viced wit h t h e
t h e ca pscr ews a t ea ch br idge. pist on pin a n d con n ect in g r od pr e-a ssem bled. Th e
(6) Tigh t en t h e ca pscr ews a lt er n a t ely, on e t u r n a t c o a te d p is to n c o n n e c tin g ro d a s s e m bly c a n be
a t im e, t o a void da m a gin g t h e br idges. Tigh t en t h e u s e d to s e rv ic e p re v io u s bu ilt e n g in e s a n d
ca pscr ews t o 28 N·m (21 ft . lbs.) t or qu e. MU S T be re p la c e d a s c o m p le te s e ts . Tin coa t ed
(7) P ou r t h e r em a in in g Mopa r ! E n gin e Oil Su pple- pist on s sh ou ld n ot be u sed a s r epla cem en t s for coa t ed
m en t , or equ iva len t over t h e en t ir e va lve a ct u a t in g pist on s.
a ssem bly. Th e Mopa r ! E n gin e Oil Su pplem en t , or (4) Th e coa t in g m a t er ia l is a pplied t o t h e pist on
equ iva len t m u st r em a in wit h t h e en gin e oil for a t a ft er t h e fin a l pist on m a ch in in g pr ocess. Mea su r in g
lea st 1 609 km (1,000 m iles). Th e oil su pplem en t t h e ou t side dia m et er of a coa t ed pist on will n ot pr o-
n eed n ot be dr a in ed u n t il t h e n ext sch edu led oil vide a ccu r a t e r esu lt s (F ig. 56). Th er efor e m ea su r in g
ch a n ge. t h e in side dia m et er of t h e cylin der bor e wit h a dia l
(8) In st a ll t h e cylin der h ea d cover (Refer t o 9 - Bor e Ga u ge is MAN D ATORY. To cor r ect ly select t h e
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD pr oper size pist on , a cylin der bor e ga u ge ca pa ble of
COVE R(S) - INSTALLATION). r ea din g in 0.003 m m (.0001 in .) in cr em en t s is
r equ ir ed.
(5) P ist on in st a lla t ion in t o t h e cylin der bor e
PI ST ON & CON N ECT I N G ROD r equ ir es sligh t ly m or e pr essu r e t h a n t h a t r equ ir ed
for n on -coa t ed pist on s. Th e bon ded coa t in g on t h e
DESCRIPTION pist on will give t h e a ppea r a n ce of a lin e-t o-lin e fit
Th e pist on s (F ig. 55) a r e m a de of a h igh st r en gt h wit h t h e cylin der bor e.
a lu m in u m a lloy, t h e pist on skir t s a r e coa t ed wit h a
solid lu br ica n t (Molykot e) t o r edu ce fr ict ion a n d pr o-
WJ ENGINE - 4.0L 9 - 45
PI ST ON & CON N ECT I N G ROD (Cont inue d)
Fig. 56 Moly Coated Piston

1 - MOLY COATED
2 - MOLY COATED
PI ST ON SI Z E CH ART
Fig. 57 Bore Gauge
CYLINDER BORE SIZE PISTON LETTER SIZE 1 - FRONT
2 - BORE GAUGE
98.438 - 98.448 mm A 3 - CYLINDER BORE
(3.8755 - 3.8759 in.) 4 - 49.5 MM (1-15/16 in.)
98.448 - 98.458 mm B
(3.8759 - 3.8763 in.)
98.458 - 98.468 mm C
(3.8763 - 3.8767 in.)
98.468 - 98.478 mm D
(3.8767 - 3.8771 in.)
98.478 - 98.488 mm E
(3.8771 - 3.8775 in.)
98.488 - 98.498 mm F
(3.8775 - 3.8779 in.)
REMOVAL
(1) Rem ove t h e en gin e cylin der h ea d cover. (Refer
H E AD COVE R(S) - RE MOVAL).
(2) Rem ove t h e r ocker a r m s, br idges a n d pivot s.
(3) Rem ove t h e pu sh r ods.
(4) Rem ove t h e en gin e cylin der h ea d. (Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL).
(5) P osit ion t h e pist on s on e a t a t im e n ea r t h e bot -
t om of t h e st r oke. Use a r idge r ea m er t o r em ove t h e Fig. 58 Main Bearings Caps and Brace
r idge fr om t h e t op en d of t h e cylin der wa lls. Use a 1 - BLOCK
pr ot ect ive clot h t o collect t h e cu t t in gs. 2 - MAIN BEARING CAP BRACE
(7) Dr a in t h e en gin e oil.
(10) Rem ove t h e con n ect in g r od bea r in g ca ps a n d
(8) Rem ove t h e oil pa n a n d ga sket . (Refer t o 9 -
in ser t s. Ma r k t h e ca ps a n d r ods wit h t h e cylin der
E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
bor e loca t ion . Th e con n ect in g r ods a n d ca ps a r e
(9) Rem ove m a in bea r in g ca p br a ce (F ig. 58).
st a m ped wit h a t wo let t er com bin a t ion (F ig. 59).
9 - 46 ENGINE - 4.0L WJ
Fig. 59 Stamped Connecting Rods and Caps

1 - CONNECTING ROD CAP
2 - CONNECTING ROD
(11) Lower t h e veh icle u n t il it is a bou t 2 feet fr om

t h e floor.
Fig. 60 Removal of Connecting Rod and Piston
CAUTION: Ensure that the connecting rod bolts DO Assembly
NOT scratch the crankshaft journals or cylinder 1 - PISTON
walls. Short pieces of rubber hose, slipped over the 2 - CONNECTING ROD
rod bolts will provide protection during removal. 3 - BLOCK
(12) H a ve a n a ssist a n t pu sh t h e pist on a n d con -

n ect in g r od a ssem blies u p a n d t h r ou gh t h e t op of t h e
cylin der bor es (F ig. 60).
INSTALLATION
(1) Clea n t h e cylin der bor es t h or ou gh ly. Apply a
ligh t film of clea n en gin e oil t o t h e bor es wit h a clea n
lin t -fr ee clot h .
(2) In st a ll t h e pist on r in gs on t h e pist on s if
r em oved (Refer t o 9 - E NGINE /E NGINE BLOCK/
P ISTON RINGS - STANDARD P ROCE DURE ).
(3) Lu br ica t e t h e pist on a n d r in gs wit h clea n
en gin e oil.
CAUTION: Ensure that connecting rod bolts DO Fig. 61 Rod and Piston Assembly Installation
NOT scratch the crankshaft journals or cylinder
is obt a in ed by u sin g va r iou s-sized, color-coded bea r-
walls. Short pieces of rubber hose slipped over the
in g in ser t s a s list ed in t h e Con n ect in g Rod Bea r in g
connecting rod bolts will provide protection during
F it t in g Ch a r t . Th e color code a ppea r s on t h e edge of
installation.
t h e bea r in g in ser t . Th e size is n ot st a m ped on in ser t s
(4) Use a pist on r in g com pr essor t o in st a ll t h e con - u sed for pr odu ct ion of en gin es.
n ect in g r od a n d pist on a ssem blies t h r ou gh t h e t op of (8) Th e r od jou r n a l is iden t ified du r in g t h e en gin e
t h e cylin der bor es (F ig. 61). pr odu ct ion by a color-coded pa in t m a r k on t h e a dja -
(5) E n su r e t h e a r r ow on t h e pist on t op poin t s t o cen t ch eek or cou n t er weigh t t owa r d t h e fla n ge (r ea r )
t h e fr on t of t h e en gin e (F ig. 61). en d of t h e cr a n ksh a ft . Th e color codes u sed t o in di-
(6) Ra ise t h e veh icle. ca t e jou r n a l sizes a r e list ed in t h e Con n ect in g Rod
(7) E a ch bea r in g in ser t is fit t ed t o it s r espect ive Bea r in g F it t in g Ch a r t .
jou r n a l t o obt a in t h e specified clea r a n ce bet ween t h e (9) Wh en r equ ir ed, u pper a n d lower bea r in g
bea r in g a n d t h e jou r n a l. In pr odu ct ion , t h e select fit in ser t s of differ en t sizes m a y be u sed a s a pa ir (r efer
WJ ENGINE - 4.0L 9 - 47
t o Con n ect in g Rod Bea r in g F it t in g Ch a r t ). A st a n -
da r d size in ser t is som et im es u sed in com bin a t ion
wit h a 0.025 m m (0.001 in ch ) u n der size in ser t t o
r edu ce clea r a n ce 0.013 m m (0.0005 in ch ).
CAUTION: DO NOT intermix bearing caps. Each

connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) In st a ll t h e con n ect in g r od bea r in g ca ps a n d

in ser t s in t h e sa m e posit ion s a s r em oved.
CAUTION: Verify that the oil squirt holes in the rods

face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(11) In st a ll m a in bea r in g ca p br a ce (F ig. 58).

Tigh t en n u t s t o 47 N·m (35 ft . lbs.).
(12) In st a ll t h e oil pa n a n d ga sket (Refer t o 9 -
E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
(13) Lower t h e veh icle. Fig. 62 Piston Dimensions
(14) In st a ll t h e en gin e cylin der h ea d (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION),
pu sh r ods, r ocker a r m s, br idges, pivot s a n d en gin e
cylin der h ea d cover (Refer t o 9 - E NGINE /CYLINDE R
H E AD/CYLINDE R H E AD COVE R(S) - INSTALLA-
TION).
(15) F ill t h e cr a n kca se wit h en gin e oil.
PI ST ON RI N GS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Ca r efu lly clea n t h e ca r bon fr om a ll r in g
gr ooves. Oil dr a in open in gs in t h e oil r in g gr oove a n d
pin boss m u st be clea r. DO NOT r em ove m et a l fr om
t h e gr ooves or la n ds. Th is will ch a n ge r in g-t o-gr oove
clea r a n ces a n d will da m a ge t h e r in g-t o-la n d sea t in g.
(2) Be su r e t h e pist on r in g gr ooves a r e fr ee of
n icks a n d bu r r s.
(3) Mea su r e t h e r in g side clea r a n ce wit h a feeler
ga u ge fit t ed sn u gly bet ween t h e r in g la n d a n d r in g
(F ig. 62) (F ig. 63). Rot a t e t h e r in g in t h e gr oove. It Fig. 63 Ring Side Clearance Measurement
m u st m ove fr eely a r ou n d cir cu m fer en ce of t h e gr oove. 1 - FEELER GAUGE
9 - 48 ENGINE - 4.0L WJ
PI ST ON RI N GS (Cont inue d)
RI N G SI DE CLEARAN CE CH ART (6) Th e t wo com pr ession r in gs a r e differ en t a n d
ca n n ot be in t er ch a n ged. Th e t op com pr ession r in g
ITEM SPECIFICATION ca n be iden t ified by t h e sh in y coa t in g on t h e ou t er
sea lin g su r fa ce a n d ca n be in st a lled wit h eit h er side
Top Compression Ring 0.042 - 0.084 mm u p. (F ig. 65).
(0.0017 - 0.0033 in.) (7) Th e secon d com pr ession r in g h a s a sligh t
Second Compression 0.042 - 0.084 mm ch a m fer on t h e bot t om of t h e in side edge a n d a dot
Ring on t h e t op for cor r ect in st a lla t ion (F ig. 66) a n d (F ig.
67).
(0.0017 - 0.0033 in.) (8) Usin g a r in g in st a ller, in st a ll t h e secon d com -
Oil Control Ring 0.06 - 0.21 mm pr ession r in g wit h t h e dot fa cin g u p (F ig. 66) (F ig.
(0.0024 - 0.0083 in.) 68).
(9) Usin g a r in g in st a ller, in st a ll t h e t op com pr es-
sion r in g (eit h er side u p).
(4) P la ce r in g in t h e cylin der bor e a n d pu sh down
wit h in ver t ed pist on t o posit ion n ea r lower en d of t h e
r in g t r a vel. Mea su r e r in g ga p wit h a feeler ga u ge fit -
t in g sn u gly bet ween r in g en ds (F ig. 64).
Fig. 65 Top Compression ring identification

1 - TOP COMPRESSION RING
Fig. 64 Gap Measurement

1 - FEELER GAUGE
RI N G GAP M EASU REM EN T CH ART
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Fig. 66 Second Compression Ring Identification
Second Compression 0.483 - 0.965 mm 1 - SECOND COMPRESSION RING
Ring 2 - CHAMFER
(0.0190 - 0.080 in.) 3 - ONE DOT
Oil Control Ring 0.254 - 1.500 mm

Ring Gap Orientation
(0.010 - 0.060 in.)
• P osit ion t h e ga ps on t h e pist on a s sh own (F ig.
69).
(5) Th e oil con t r ol r in gs a r e sym m et r ica l, a n d ca n
• Oil spa cer - Ga p on cen t er lin e of pist on skir t .
be in st a lled wit h eit h er side u p. It is n ot n ecessa r y t o
• Oil r a ils - ga p 180° a pa r t on cen t er lin e of pist on
u se a t ool t o in st a ll t h e u pper a n d lower r a ils. In ser t
pin bor e.
oil r a il spa cer fir st , t h en side r a ils.
• No. 2 Com pr ession r in g - Ga p 180° fr om t op oil
r a il ga p.
WJ ENGINE - 4.0L 9 - 49
Fig. 67 Compression Ring Chamfer Location

2 - SECOND COMPRESSION RING
3 - PISTON
4 - CHAMFER
Fig. 69 Ring Gap Orientation

2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 68 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
• No. 1 Com pr ession r in g - Ga p 180° fr om No. 2

com pr ession r in g ga p.
V I BRAT I ON DAM PER

REMOVAL
(2) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 -
RE MOVAL) a n d fa n sh r ou d.
(3) Rem ove t h e vibr a t ion da m per r et a in in g bolt
a n d wa sh er.
(4) Use Vibr a t ion Da m per Rem ova l Tool 7697 t o Fig. 70 Vibration Damper Removal Tool 7697
r em ove t h e da m per fr om t h e cr a n ksh a ft (F ig. 70). 1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH
9 - 50 ENGINE - 4.0L WJ
V I BRAT I ON DAM PER (Cont inue d)
INSTALLATION (4) Tigh t en en gin e-t o-t r a n sm ission br a ce r et a in in g

(1) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l- bolt (F ig. 71)t o 40 N·m (30 ft . lbs.).
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e (5) Tigh t en t r a n sm ission br a ce r et a in in g bolt s (F ig.
key. Wit h t h e key in posit ion , a lign t h e keywa y on 72)t o 40 N·m (30 ft . lbs.), t h en t igh t en t r a n sm ission
t h e vibr a t ion da m per h u b wit h t h e cr a n ksh a ft key br a ce r et a in in g lock n u t s (F ig. 72) t o 108 N·m (80 ft .
a n d t a p t h e da m per on t o t h e cr a n ksh a ft . lbs.).
(2) In st a ll t h e vibr a t ion da m per r et a in in g bolt a n d
wa sh er.
(3) Tigh t en t h e da m per r et a in in g bolt t o 108 N·m
(80 ft . lbs.) t or qu e.
(4) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
INSTALLATION) a n d fa n sh r ou d.
ST RU CT U RAL SU PPORT
REMOVAL
Th e en gin e ben din g br a ces a r e u sed t o a dd
st r en gt h t o t h e power t r a in a n d t o a ddr ess som e
m in or NVH con cer n s.
NOTE: Before the engine or the transmission can

be removed the engine bending braces must be
removed. Fig. 71 Engine-to-Transmission Bending Braces
1 - ENGINE-TO-TRANSMISSION BENDING BRACE
(1) Ra ise a n d su ppor t veh icle.
2 - CROSS BRACE
3 - ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
NOTE: Both left and right side bending braces are BOLT
removed the sameway. Only the right side is
shown.
LU BRI CAT I ON
NOTE: The exhaust does not require removal to
preform this procedure. DESCRIPTION
A gea r —t ype posit ive displa cem en t pu m p is
(2) Rem ove t h e exh a u st h a n ger br a cket r et a in in g m ou n t ed a t t h e u n der side of t h e block opposit e t h e
bolt . No. 4 m a in bea r in g.
(3) Rem ove lockn u t a n d t r a n sm ission ben din g
br a ce ba r. OPERATION
(4) Rem ove en gin e-t o-ben din g br a ce r et a in in g bolt , Th e pu m p dr a ws oil t h r ou gh t h e scr een a n d in let
ben din g br a ce ba r a n d cr oss ba r. t u be fr om t h e su m p a t t h e r ea r of t h e oil pa n . Th e oil
is dr iven bet ween t h e dr ive a n d idler gea r s a n d
INSTALLATION pu m p body, t h en for ced t h r ou gh t h e ou t let t o t h e
block. An oil ga ller y in t h e block ch a n n els t h e oil t o
NOTE: DO NOT tighten the retaining hardware until t h e in let side of t h e fu ll flow oil filt er. Aft er pa ssin g
all bending braces are in place. t h r ou gh t h e filt er elem en t , t h e oil pa sses fr om t h e
cen t er ou t let of t h e filt er t h r ou gh a n oil ga ller y t h a t
(1) P osit ion t h e cr oss br a ce in t o t h e en gin e-t o- ch a n n els t h e oil u p t o t h e m a in ga ller y wh ich
t r a n sm ission br a ce, t h en posit ion t h e en gin e-t o-t r a n s- ext en ds t h e en t ir e len gt h of t h e block.
m ission br a ce a n d in st a ll r et a in in g bolt . Ga ller ies ext en d down wa r d fr om t h e m a in oil ga l-
(2) P osit ion t h e t r a n sm ission ben din g br a ce on t o ler y t o t h e u pper sh ell of ea ch m a in bea r in g. Th e
t h r ou gh br a ce a n d in st a ll n ew lockn u t . cr a n ksh a ft is dr illed in t er n a lly t o pa ss oil fr om t h e
(3) P osit ion exh a u st h a n ger a n d t r a n sm ission m a in bea r in g jou r n a ls (except n u m ber 4 m a in bea r-
br a ce, in st a ll r et a in in g bolt (F ig. 72). in g jou r n a l) t o t h e con n ect in g r od jou r n a ls. E a ch con -
n ect in g r od bea r in g ca p h a s a sm a ll squ ir t h ole, oil
WJ ENGINE - 4.0L 9 - 51
LU BRI CAT I ON (Cont inue d)
DIAGNOSIS AND TESTING - ENGINE OIL LEAK

Begin wit h a t h or ou gh visu a l in spect ion of t h e
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
followin g st eps sh ou ld be followed:
(1) Do n ot clea n or degr ea se t h e en gin e a t t h is
t im e beca u se som e solven t s m a y ca u se r u bber t o
swell, t em por a r ily st oppin g t h e lea k.
(2) Add a n oil solu ble dye (u se a s r ecom m en ded by
m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
wit h a br igh t yellow color u n der a bla ck ligh t .
(3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
r epa ir per ser vice m a n u a l in st r u ct ion s.
(4) If dye is n ot obser ved, dr ive t h e veh icle a t va r-
iou s speeds for a ppr oxim a t ely 24km (15 m iles), a n d
Fig. 72 Transmission Bending Braces and Exhaust r epea t in spect ion .
Hanger (4) If th e o il le a k s o u rc e is n o t p o s itiv e ly
id e n tifie d a t th is tim e , pr oceed wit h t h e a ir lea k
1 - TRANSMISSION BENDING BRACE RETAINING BOLT
2 - ENGINE-TO-TRANSMISSION BENDING BRACE
det ect ion t est m et h od.
3 - LOCKNUT
4 - TRANSMISSION BRACE Air Leak Detection Test Method
5 - EXHAUST HANGER (1) Discon n ect t h e br ea t h er ca p t o a ir clea n er h ose
a t t h e br ea t h er ca p en d. Ca p or plu g br ea t h er ca p
n ipple.
pa sses t h r ou gh t h e squ ir t h ole a n d is t h r own off a s
(2) Rem ove t h e CCV va lve fr om t h e cylin der h ea d
t h e r od r ot a t es. Th is oil t h r owoff lu br ica t es t h e ca m -
cover. Ca p or plu g t h e CCV va lve gr om m et .
sh a ft lobes, dist r ibu t or dr ive gea r, cylin der wa lls, a n d
(3) At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d
pist on pin s.
r egu la t or t o t h e dipst ick t u be.
Th e h ydr a u lic va lve t a ppet s r eceive oil dir ect ly
fr om t h e m a in oil ga ller y. Oil is pr ovided t o t h e ca m - CAUTION: Do not subject the engine assembly to
sh a ft bea r in g t h r ou gh ga ller ies. Th e fr on t ca m sh a ft more than 20.6 kpa (3 PSI) of test pressure.
bea r in g jou r n a l pa sses oil t h r ou gh t h e ca m sh a ft
spr ocket t o t h e t im in g ch a in . Oil dr a in s ba ck t o t h e (4) Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5
oil pa n u n der t h e n u m ber on e m a in bea r in g ca p. psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s-
Th e oil su pply for t h e r ocker a r m s a n d br idged pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble
pivot a ssem blies is pr ovided by t h e h ydr a u lic va lve t est pr essu r e t h a t pr ovide t h e best bu bbles wh ich
t a ppet s wh ich pa ss oil t h r ou gh h ollow pu sh r ods t o a will pin poin t t h e lea k sou r ce. If t h e oil lea k is
h ole in t h e cor r espon din g r ocker a r m . Oil fr om t h e det ect ed a n d iden t ified, r epa ir per ser vice in for m a -
r ocker a r m lu br ica t es t h e va lve t r a in com pon en t s, t ion pr ocedu r es.
t h en pa sses down t h r ou gh t h e pu sh r od gu ide h oles (5) If t h e lea ka ge occu r s a t t h e r ea r oil sea l a r ea ,
in t h e cylin der h ea d pa st t h e va lve t a ppet a r ea , a n d INSP E CTION F OR RE AR SE AL ARE A LE AKS .
r et u r n s t o t h e oil pa n (F ig. 73). (6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply
a n d r em ove t h e a ir h ose a n d a ll plu gs a n d ca ps.
DIAGNOSIS AND TESTING - ENGINE OIL In st a ll t h e CCV va lve a n d br ea t h er ca p h ose.
PRESSURE (7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g
(1) Discon n ect con n ect or a n d r em ove oil pr essu r e a su it a ble solven t . Dr ive t h e veh icle a t va r iou s
sen din g u n it . speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e
(2) In st a ll Oil P r essu r e Lin e a n d Ga u ge Tool en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t .
C-3292 or equ iva len t . St a r t en gin e a n d r ecor d pr es-
su r e. (Refer t o 9 - E NGINE - SP E CIF ICATIONS) for INSPECTION FOR REAR SEAL AREA LEAKS
t h e cor r ect pr essu r es. Sin ce it is som et im es difficu lt t o det er m in e t h e
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
9 - 52 ENGINE - 4.0L WJ
Fig. 73 Oil Lubrication System—4.0L Engine

1 - CAM/CRANK MAIN GALLERY (7) 5 - NUMBER 1 CAMSHFT BEARING JOURNAL
2 - TAPPET GALLERY 6 - CAMSHAFT SPROCKET
3 - TAPPET GALLERY 7 - TAPPET GALLERY
4 - CAMSHAFT BEARING
WJ ENGINE - 4.0L 9 - 53
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e (4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
followin g st eps sh ou ld be followed t o h elp pin poin t dr a in .
t h e sou r ce of t h e lea k. (5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l oil t o dr a in in t o pa n . In spect dr a in plu g t h r ea ds for
a r ea : st r et ch in g or ot h er da m a ge. Repla ce dr a in plu g if
(1) Discon n ect t h e ba t t er y. da m a ged.
(2) Ra ise t h e veh icle. (6) In st a ll dr a in plu g in cr a n kca se.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g (7) Repla ce en gin e oil filt er. (Refer t o 9 - E NGINE /
cover a n d in spect r ea r of block for eviden ce of oil. LUBRICATION/OIL F ILTE R - RE MOVAL).
Use a bla ck ligh t t o ch eck for t h e oil lea k: (8) Lower veh icle a n d fill cr a n kca se wit h specified
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es t ype of en gin e oil (Refer t o LUBRICATION & MAIN-
sea l lea ka ge or cr a n ksh a ft da m a ge. TE NANCE /F LUID TYP E S - DE SCRIP TION) a n d
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down , a m ou n t of en gin e oil (Refer t o LUBRICATION &
possible ca u ses a r e a por ou s block, dist r ibu t or sea l, MAINTE NANCE - SP E CIF ICATIONS).
ca m sh a ft bor e cu p plu gs oil ga lley pipe plu gs, oil (9) In st a ll oil fill ca p.
filt er r u n off, a n d m a in bea r in g ca p t o cylin der (10) St a r t en gin e a n d in spect for lea ks.
block m a t in g su r fa ces. (11) St op en gin e a n d in spect oil level. Refer t o
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k- CRANKCASE OIL LE VE L INSP E CTION .
ca se a s ou t lin ed in t h e, In spect ion (E n gin e oil Lea ks
in gen er a l) USED ENGINE OIL DISPOSAL
Ca r e sh ou ld be exer cised wh en disposin g u sed
CAUTION: Do not exceed 20.6 kPa (3 psi). en gin e oil a ft er it h a s been dr a in ed fr om a veh icle
en gin e.
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is CRANKCASE OIL LEVEL INSPECTION
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e CAUTION: Do not overfill crankcase with engine oil,
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on oil foaming and oil pressure loss can result.
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es
t h a t ca n be polish ed ou t wit h em er y clot h . Th e en gin e oil level in dica t or (Dipst ick) is loca t ed
a t t h e r igh t r ea r of t h e 4.0L en gin e. In spect en gin e
CAUTION: Use extreme caution when crankshaft oil level a ppr oxim a t ely ever y 800 kilom et er s (500
polishing is necessary to remove minor nicks and m iles). Un less t h e en gin e h a s exh ibit ed loss of oil
scratches. The crankshaft seal flange is especially pr essu r e, r u n t h e en gin e for a bou t five m in u t es
machined to complement the function of the rear oil befor e ch eckin g oil level. Ch eckin g en gin e oil level on
seal. a cold en gin e is n ot a ccu r a t e.
To en su r e pr oper lu br ica t ion of a n en gin e, t h e
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft en gin e oil m u st be m a in t a in ed a t a n a ccept a ble level.
r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis- Th e a ccept a ble levels a r e in dica t ed bet ween t h e ADD
a ssem bled. a n d SAF E m a r ks on t h e en gin e oil dipst ick (F ig. 74).
(1) P osit ion veh icle on level su r fa ce.
(2) Wit h en gin e OF F, a llow a ppr oxim a t ely t en m in -
OI L u t es for oil t o set t le t o bot t om of cr a n kca se, r em ove
en gin e oil dipst ick.
STANDARD PROCEDURE - ENGINE OIL (3) Wipe dipst ick clea n .
SERVICE (4) In st a ll dipst ick a n d ver ify it is sea t ed in t h e
t u be.
ENGINE OIL CHANGE (5) Rem ove dipst ick, wit h h a n dle h eld a bove t h e
Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls t ip, t a ke oil level r ea din g (F ig. 74).
descr ibed in Ma in t en a n ce Sch edu les.
Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em -
per a t u r e.
(1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n
en gin e off.
(2) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(3) Rem ove oil fill ca p.
9 - 54 ENGINE - 4.0L WJ
OI L (Cont inue d)
(6) Add oil on ly if level is below t h e ADD m a r k on
dipst ick.
Fig. 75 Oil Filter—4.0L Engine

1 - CYLINDER BLOCK
Fig. 74 Engine Oil Dipstick—4.0L Engine 2 - ADAPTER
1 - DIPSTICK 3 - OIL FILTER
2 - ADD
3 - SAFE (3) Add oil, ver ify cr a n kca se oil level a n d st a r t
en gin e. In spect for oil lea ks.
OI L FI LT ER
REMOVAL
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
All J eep en gin es a r e equ ipped wit h a h igh qu a lit y

fu ll-flow, t h r ow-a wa y t ype oil filt er. Da im ler Ch r ysler
Cor por a t ion r ecom m en ds a Mopa r ! or equ iva len t oil
filt er be u sed. Fig. 76 Oil Filter Sealing Surface—Typical
(1) P osit ion a dr a in pa n u n der t h e oil filt er.
1 - SEALING SURFACE
(2) Usin g a su it a ble oil filt er wr en ch loosen filt er.
2 - RUBBER GASKET
(3) Rot a t e t h e oil filt er cou n t er clockwise t o r em ove 3 - OIL FILTER
it fr om t h e cylin der block oil filt er boss or filt er
a da pt er h ou sin g (F ig. 75).
(4) Wh en filt er sepa r a t es fr om a da pt er n ipple, t ip OI L PAN
ga sket en d u pwa r d t o m in im ize oil spill. Rem ove fil-
t er fr om veh icle.
(5) Ma ke su r e old ga sket com es off wit h oil filt er.
DESCRIPTION
Th e oil pa n is m a de of st a m ped st eel. Th e oil pa n
Wit h a wipin g clot h , clea n t h e ga sket sea lin g su r fa ce
ga sket is a on e piece st eel ba ckbon e silicon e coa t ed
(F ig. 76) of oil a n d gr im e.
ga sket (F ig. 77).
INSTALLATION
(1) Ligh t ly lu br ica t e oil filt er ga sket wit h en gin e
REMOVAL
oil or ch a ssis gr ea se.
(2) Th r ea d filt er on t o a da pt er n ipple. Wh en ga sket
(3) Rem ove t h e oil pa n dr a in plu g a n d dr a in t h e
m a kes con t a ct wit h sea lin g su r fa ce, (F ig. 76) h a n d
en gin e oil.
t igh t en filt er on e fu ll t u r n , do n ot over t igh t en .
(4) Discon n ect t h e exh a u st pipe a t t h e exh a u st
m a n ifold.
WJ ENGINE - 4.0L 9 - 55
OI L PAN (Cont inue d)
Fig. 78 Fabrication of Alignment Dowels

1 - 1/4## ! 1 1/2## BOLT
2 - DOWEL
Fig. 77 Oil Pan 3 - SLOT
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
(5) Discon n ect t h e exh a u st h a n ger a t t h e ca t a lyt ic

con ver t er a n d lower t h e pipe.
(6) Rem ove t h e st a r t er m ot or. (Refer t o 8 - E LE C-
TRICAL/STARTING/STARTE R MOTOR - RE MOV-
AL).
(7) Rem ove t h e en gin e flywh eel a n d t r a n sm ission
t or qu e con ver t er h ou sin g a ccess cover.
(8) If equ ipped wit h a n oil level sen sor, discon n ect
t h e sen sor.
(9) P osit ion a ja ck st a n d dir ect ly u n der t h e en gin e
vibr a t ion da m per.
(10) P la ce a piece of wood (2 x 2) bet ween t h e ja ck
st a n d a n d t h e en gin e vibr a t ion da m per.
(11) Rem ove t h e en gin e m ou n t t h r ou gh bolt s.
(12) Usin g t h e ja ck st a n d, r a ise t h e en gin e u n t il Fig. 79 Position of Dowels in Cylinder Block
a dequ a t e clea r a n ce is obt a in ed t o r em ove t h e oil pa n . 1 - DOWEL HOLES
(13) Rem ove t r a n sm ission oil coolin g lin es (if 2 - CYLINDER BLOCK
equ ipped) a n d oxygen sen sor wir in g su ppor t s t h a t 3 - 5/16## HOLES
a r e a t t a ch ed t o t h e oil pa n st u ds. 4 - 5/16## HOLES
(14) Rem ove t h e oil pa n bolt s a n d st u ds. Ca r efu lly
slide t h e oil pa n a n d ga sket t o t h e r ea r. If equ ipped n er s a n d cylin der block t o fr on t cover join t s (fou r
wit h a n oil level sen sor, t a ke ca r e n ot t o da m a ge t h e pla ces) (F ig. 80).
sen sor. (5) Slide t h e on e-piece ga sket over t h e dowels a n d
on t o t h e block a n d t im in g ca se cover.
INSTALLATION (6) P osit ion t h e oil pa n over t h e dowels a n d on t o
(1) Clea n t h e block a n d pa n ga sket su r fa ces. t h e ga sket . If equ ipped wit h a n oil level sen sor, t a ke
(2) F a br ica t e 4 a lign m en t dowels fr om 1 1/2 x 1/4 ca r e n ot t o da m a ge t h e sen sor.
in ch bolt s. Cu t t h e h ea d off t h e bolt s a n d cu t a slot (7) In st a ll t h e 1/4 in ch oil pa n bolt s. Tigh t en t h ese
in t o t h e t op of t h e dowel. Th is will a llow ea sier bolt s t o 9.5 N·m (84 in . lbs.) t or qu e. In st a ll t h e 5/16
in st a lla t ion a n d r em ova l wit h a scr ewdr iver (F ig. 78). in ch oil pa n bolt s (F ig. 81). Tigh t en t h ese bolt s t o 15
(3) In st a ll t wo dowels in t h e t im in g ca se cover. N·m (132 in . lbs.) t or qu e.
In st a ll t h e ot h er t wo dowels in t h e cylin der block (8) Rem ove t h e dowels. In st a ll t h e r em a in in g 1/4
(F ig. 79). in ch oil pa n bolt s. Tigh t en t h ese bolt s t o 9.5 N·m (84
(4) Apply Mopa r ! Silicon e Ru bber Adh esive Sea l- in . lbs.) t or qu e.
a n t on cylin der block t o r ea r m a in bea r in g ca p cor- (9) Lower t h e en gin e u n t il it is pr oper ly loca t ed on
t h e en gin e m ou n t s.
9 - 56 ENGINE - 4.0L WJ
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(20) St a r t t h e en gin e a n d in spect for lea ks.
EN GI N E OI L PRESSU RE
SEN SOR
DESCRIPTION
Th e 3–wir e, solid-st a t e en gin e oil pr essu r e sen sor
(sen din g u n it ) is loca t ed in a n en gin e oil pr essu r e
ga ller y.
Fig. 80 Oil Pan Sealer Location
1 - SEALER LOCATIONS OPERATION
Th e oil pr essu r e sen sor u ses t h r ee cir cu it s. Th ey
a r e:
• A 5–volt power su pply fr om t h e P ower t r a in Con -
t r ol Modu le (P CM)
• A sen sor gr ou n d t h r ou gh t h e P CM’s sen sor
r et u r n
• A sign a l t o t h e P CM r ela t in g t o en gin e oil pr es-
su r e
Th e oil pr essu r e sen sor h a s a 3–wir e elect r ica l
fu n ct ion ver y m u ch like t h e Ma n ifold Absolu t e P r es-
su r e (MAP ) sen sor. Mea n in g differ en t pr essu r es
r ela t e t o differ en t ou t pu t volt a ges.
A 5–volt su pply is sen t t o t h e sen sor fr om t h e P CM
t o power u p t h e sen sor. Th e sen sor r et u r n s a volt a ge
Fig. 81 Position of 5/16 inch Oil Pan Bolts sign a l ba ck t o t h e P CM r ela t in g t o en gin e oil pr es-
1 - OIL PAN su r e. Th is sign a l is t h en t r a n sfer r ed (bu ssed) t o t h e
2 - OIL PAN DRAIN PLUG in st r u m en t pa n el on eit h er a CCD or P CI bu s cir cu it
(depen din g on veh icle lin e) t o oper a t e t h e oil pr essu r e
(10) In st a ll t h e t h r ou gh bolt s a n d t igh t en t h e n u t s. ga u ge a n d t h e ch eck ga u ges la m p. Gr ou n d for t h e
(11) Lower t h e ja ck st a n d a n d r em ove t h e piece of sen sor is pr ovided by t h e P CM t h r ou gh a low-n oise
wood. sen sor r et u r n .
(12) In st a ll t h e en gin e flywh eel a n d t r a n sm ission
t or qu e con ver t er h ou sin g a ccess cover.
(13) In st a ll t h e en gin e st a r t er m ot or. (Refer t o 8 - OI L PU M P
E LE CTRICAL/STARTING/STARTE R MOTOR -
INSTALLATION). REMOVAL
(14) Con n ect t h e exh a u st pipe t o t h e h a n ger a n d t o A gea r-t ype oil pu m p is m ou n t ed a t t h e u n der side
t h e en gin e exh a u st m a n ifold. of t h e cylin der block opposit e t h e No.4 m a in bea r in g.
(15) In st a ll t r a n sm ission oil coolin g lin es (if (1) Dr a in t h e en gin e oil.
equ ipped) a n d oxygen sen sor wir in g su ppor t s t h a t (2) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
a t t a ch t o t h e oil pa n st u ds. BRICATION/OIL PAN - RE MOVAL).
(16) In st a ll t h e oil pa n dr a in plu g (F ig. 81). (3) Rem ove t h e pu m p-t o-cylin der block a t t a ch in g
Tigh t en t h e plu g t o 34 N·m (25 ft . lbs.) t or qu e. bolt s. Rem ove t h e pu m p a ssem bly wit h ga sket (F ig.
(17) Lower t h e veh icle. 82).
(19) F ill t h e oil pa n wit h en gin e oil t o t h e specified CAUTION: If the oil pump is not to be serviced, DO
level. NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
WARNING: USE EXTREME CAUTION WHEN THE the pump body, a replacement tube and strainer
ENGINE IS OPERATING. DO NOT STAND IN A assembly must be installed to assure an airtight
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR seal.
WJ ENGINE - 4.0L 9 - 57
OI L PU M P (Cont inue d)
Fig. 83 Intake Manifold 4.0L Engine

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) St a r t t h e en gin e.
Fig. 82 Oil Pump Assembly (2) Spr a y a sm a ll st r ea m of wa t er a t t h e su spect ed
1 - OIL FILTER ADAPTOR lea k a r ea .
2 - BLOCK (3) If a ch a n ge in RP M is obser ved t h e a r ea of t h e
3 - GASKET su spect ed lea k h a s been fou n d.
4 - OIL INLET TUBE (4) Repa ir a s r equ ir ed.
5 - OIL PUMP
6 - STRAINER ASSEMBLY
REMOVAL
7 - ATTACHING BOLTS
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
INSTALLATION
TOGETHER. THE MANIFOLDS USE A COMMON
A gea r-t ype oil pu m p is m ou n t ed a t t h e u n der side
GASKET AT THE CYLINDER HEAD.
of t h e cylin der block opposit e t h e No.4 m a in bea r in g.
(1) In st a ll t h e oil pu m p on t h e cylin der block u sin g (1) Discon n ect t h e ba t t er y n ega t ive ca ble.
a r epla cem en t ga sket . Tigh t en t h e bolt s t o 23 N·m (2) Rem ove a ir clea n er in let h ose fr om t h e r eson a -
(17 ft . lbs.) t or qu e. t or a ssem bly.
(2) In st a ll t h e oil pa n (Refer t o 9 - E NGINE /LU- (3) Rem ove t h e a ir clea n er a ssem bly.
BRICATION/OIL PAN - INSTALLATION). (4) Rem ove t h e t h r ot t le ca ble, veh icle speed con t r ol
(3) F ill t h e oil pa n wit h oil t o t h e specified level. ca ble (if equ ipped) a n d t h e t r a n sm ission lin e pr es-
su r e ca ble (Refer t o 21 - TRANSMISSION/TRAN-
SAXLE /AUTOMATIC - AW4/TH ROTTLE VALVE
I N TAK E M AN I FOLD CABLE - RE MOVAL).
(5) Discon n ect t h e followin g elect r ica l con n ect ion s
DESCRIPTION a n d secu r e t h eir h a r n ess ou t of t h e wa y:
Th e in t a ke m a n ifold (F ig. 83) is m a de of ca st a lu - • Th r ot t le P osit ion Sen sor
m in u m a n d u ses eleven bolt s t o m ou n t t o t h e cylin - • Idle Air Con t r ol Mot or
der h ea d. Th is m ou n t in g st yle im pr oves sea lin g a n d • Coola n t Tem per a t u r e Sen sor (a t t h er m ost a t
r edu ces t h e ch a n ce of lea ks. h ou sin g)
• In t a ke Air Tem per a t u r e Sen sor
DIAGNOSIS AND TESTING - INTAKE • Oxygen Sen sor
MANIFOLD LEAKAGE DIAGNOSIS • Cr a n k P osit ion Sen sor
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by • Six (6) F u el In ject or Con n ect or s
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or • Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor.
m or e cylin der s m a y n ot be fu n ct ion in g.
9 - 58 ENGINE - 4.0L WJ
I N TAK E M AN I FOLD (Cont inue d)
(6) Discon n ect H VAC, a n d Br a ke Boost er va cu u m
su pply h oses a t t h e in t a ke m a n ifold.
(7) P er for m t h e fu el pr essu r e r elea se pr ocedu r e.
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
(8) Discon n ect a n d r em ove t h e fu el syst em su pply
lin e fr om t h e fu el r a il a ssem bly.
(9) Rem ove t h e a ccessor y dr ive belt (Refer t o 7 -
RE MOVAL).
(10) Rem ove t h e power st eer in g pu m p fr om t h e
in t a ke m a n ifold a n d set a side.
(12) Discon n ect t h e exh a u st pipes fr om t h e en gin e
exh a u st m a n ifolds.
(13) Lower t h e veh icle.
(14) Rem ove t h e in t a ke m a n ifold a n d exh a u st Fig. 84 Intake and Exhaust Manifolds Installation
m a n ifold bolt s a n d m a n ifolds (F ig. 84). (8) In st a ll t h e a ccessor y dr ive belt (Refer t o 7 -
INSTALLATION INSTALLATION).
If t h e m a n ifold is bein g r epla ced, en su r e a ll t h e fit - (9) In st a ll t h e fu el syst em su pply lin e t o t h e fu el
t in g, et c. a r e t r a n sfer r ed t o t h e r epla cem en t m a n i- r a il a ssem bly.
fold. (10) Con n ect a ll elect r ica l con n ect ion s on t h e
(1) In st a ll a n ew en gin e exh a u st /in t a ke m a n ifold in t a ke m a n ifold.
ga sket over t h e a lign m en t dowels on t h e cylin der (11) Con n ect t h e va cu u m h oses pr eviou sly
h ea d. r em oved.
(2) P osit ion t h e en gin e exh a u st m a n ifolds t o t h e (12) In st a ll t h r ot t le ca ble, veh icle speed con t r ol
cylin der h ea d. In st a ll fa st en er Nu m ber 3 a n d fin ger ca ble (if equ ipped).
t igh t en a t t h is t im e (F ig. 84). (13) In st a ll t h e t r a n sm ission lin e pr essu r e ca ble (if
(3) In st a ll in t a ke m a n ifold on t h e cylin der h ea d equ ipped) (Refer t o 21 - TRANSMISSION/TRANS-
dowels. AXLE /AUTOMATIC - AW4/TH ROTTLE VALVE
(4) In st a ll wa sh er a n d fa st en er Nu m ber s 1, 2, 4, 5, CABLE - INSTALLATION).
8, 9, 10 a n d 11 (F ig. 84). (14) In st a ll a ir clea n er a ssem bly.
(5) In st a ll wa sh er a n d fa st en er Nu m ber s 6 a n d 7 (15) Con n ect a ir in let h ose t o t h e r eson a t or a ssem -
(F ig. 84). bly.
(6) Tigh t en t h e fa st en er s in sequ en ce a n d t o t h e (16) Ra ise t h e veh icle.
specified t or qu e (F ig. 84). (17) Con n ect t h e exh a u st pipes t o t h e en gin e
• F a st en er Nu m ber s 1 t h r ou gh 5—Tigh t en t o 33 exh a u st m a n ifolds. Tigh t en t h e bolt s t o 31 N·m (23
N·m (24 ft . lbs.) t or qu e. ft . lbs.)
• F a st en er Nu m ber s 6 a n d 7—Tigh t en t o 31 N·m (18) Lower t h e veh icle.
(23 ft . lbs.) t or qu e. (19) Con n ect t h e ba t t er y n ega t ive ca ble.
• F a st en er Nu m ber s 8 t h r ou gh 11—Tigh t en t o 33 (20) St a r t t h e en gin e a n d ch eck for lea ks.
(7) In st a ll t h e power st eer in g pu m p t o t h e in t a ke
m a n ifold.
WJ ENGINE - 4.0L 9 - 59
EX H AU ST M AN I FOLD (5) Rem ove t h e A/C com pr essor (Refer t o 24 -

H E ATING & AIR CONDITIONING/P LUMBING/A/C
COMP RE SSOR - RE MOVAL) (if equ ipped) a n d gen -
DESCRIPTION
er a t or br a cket a ssem bly fr om t h e en gin e cylin der
Th e t wo exh a u st m a n ifolds (F ig. 85) a r e log st yle
h ea d a n d m ove t o on e side.
a n d a r e m a de of h igh silicon m olybden u m ca st ir on .
(6) Rem ove t h e oil pa n -t o-t im in g ca se cover bolt s
Th e exh a u st m a n ifolds sh a r e a com m on ga sket wit h
a n d t im in g ca se cover-t o-cylin der block bolt s.
t h e in t a ke m a n ifold. Th e exh a u st m a n ifolds a lso
(7) Rem ove t h e t im in g ca se cover a n d ga sket fr om
in cor por a t e ba ll fla n ge ou t let s for im pr oved sea lin g
t h e en gin e.
a n d st r a in fr ee con n ect ion s.
(8) P r y t h e cr a n ksh a ft oil sea l fr om t h e fr on t of t h e
t im in g ca se cover (F ig. 86).
REMOVAL
Th e in t a ke a n d en gin e exh a u st m a n ifolds on t h e
4.0L en gin e m u st be r em oved t oget h er. Th e m a n ifolds
u se a com m on ga sket a t t h e cylin der h ea d.
(Refer t o 9 - E NGINE /MANIF OLDS/INTAKE
MANIF OLD - RE MOVAL).
INSTALLATION
(1) Th e exh a u st m a n ifold a n d t h e in t a ke m a n ifold
m u st be in st a lled t oget h er u sin g a com m on ga sket .
(2) (Refer t o 9 - E NGINE /MANIF OLDS/INTAKE
MANIF OLD - INSTALLATION).
T I M I N G BELT / CH AI N
COV ER(S) Fig. 86 Timing Case Cover Components
1 - TIMING CASE COVER
REMOVAL 2 - OIL SLINGER
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. 3 - CRANKSHAFT OIL SEAL
(2) Rem ove t h e vibr a t ion da m per (Refer t o 9 - 4 - VIBRATION DAMPER PULLEY
RE MOVAL).
(3) Rem ove t h e fa n , h u b a ssem bly a n d fa n sh r ou d
(Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
RE MOVAL).
(4) Rem ove t h e a ccessor y dr ive br a cket s t h a t a r e
a t t a ch ed t o t h e t im in g ca se cover.
Fig. 85 EXHAUST MANIFOLDS 4.0L ENGINE

9 - 60 ENGINE - 4.0L WJ
T I M I N G BELT / CH AI N COV ER(S) (Cont inue d)
INSTALLATION (11) In st a ll t h e en gin e fa n , h u b a ssem bly a n d

Clea n t h e t im in g ca se cover, oil pa n a n d cylin der sh r ou d (Refer t o 7 - COOLING/E NGINE /RADIATOR
block ga sket su r fa ces. FAN - INSTALLATION).
(1) In st a ll a n ew cr a n ksh a ft oil sea l in t h e t im in g (12) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
ca se cover. Th e open en d of t h e sea l sh ou ld be t owa r d COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
t h e in side of t h e cover. Su ppor t t h e cover a t t h e sea l INSTALLATION).
a r ea wh ile in st a llin g t h e sea l. F or ce it in t o posit ion (13) Con n ect n ega t ive ca ble t o ba t t er y.
wit h Sea l In st a lla t ion Tool 6139.
(2) P osit ion t h e ga sket on t h e cylin der block.
(3) P osit ion t h e t im in g ca se cover on t h e oil pa n
T I M I N G BELT /CH AI N AN D
ga sket a n d t h e cylin der block. SPROCK ET S
(4) In ser t Tim in g Ca se Cover Align m en t a n d Sea l
In st a lla t ion Tool 6139 in t h e cr a n ksh a ft open in g in REMOVAL
t h e cover (F ig. 87). (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove t h e fa n a n d sh r ou d (Refer t o 7 -
COOLING/E NGINE /RADIATOR FAN - RE MOVAL).
(3) Rem ove t h e ser pen t in e dr ive belt (Refer t o 7 -
RE MOVAL).
(4) Rem ove t h e cr a n ksh a ft vibr a t ion da m per (Refer
t o 9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - RE MOVAL).
(5) Rem ove t h e t im in g ca se cover (Refer t o 9 -
(6) Rot a t e cr a n ksh a ft u n t il t h e “0” t im in g m a r k is
closest t o a n d on t h e cen t er lin e wit h ca m sh a ft
spr ocket t im in g m a r k (F ig. 88).
Fig. 87 Timing Case Cover Alignment

1 - TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
(5) In st a ll t h e t im in g ca se cover-t o-cylin der block

a n d t h e oil pa n -t o-t im in g ca se cover bolt s.
(6) Tigh t en t h e 1/4 in ch cover-t o-block bolt s t o 7
N·m (60 in . lbs.) t or qu e. Tigh t en t h e 5/16 in ch fr on t
cover-t o-block bolt s t o 22 N·m (192 in . lbs.) t or qu e.
Tigh t en t h e oil pa n -t o-cover 1/4 in ch bolt s t o 9.5 N·m
(84 in . lbs.) t or qu e.
(7) Rem ove t h e cover a lign m en t t ool.
(8) Apply a ligh t film of en gin e oil on t h e vibr a t ion
da m per h u b con t a ct su r fa ce of t h e sea l.
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
key. Wit h t h e key in ser t ed in t h e keywa y in t h e
cr a n ksh a ft , in st a ll t h e vibr a t ion da m per (Refer t o 9 -
INSTALLATION).
(10) In st a ll t h e A/C com pr essor (Refer t o 24 - Fig. 88 Crankshaft—Camshaft Alignment
H E ATING & AIR CONDITIONING/P LUMBING/A/C
COMP RE SSOR - INSTALLATION) (if equ ipped) a n d 2 - TIMING MARKS
gen er a t or br a cket a ssem bly. 3 - CRANKSHAFT SPROCKET
WJ ENGINE - 4.0L 9 - 61
T I M I N G BELT /CH AI N AN D SPROCK ET S (Cont inue d)
(7) Rem ove t h e oil slin ger fr om t h e cr a n ksh a ft . INSTALLATION
(8) Rem ove t h e ca m sh a ft spr ocket bolt a n d wa sh er Assem ble t h e t im in g ch a in , cr a n ksh a ft spr ocket
(F ig. 89). a n d ca m sh a ft spr ocket wit h t h e t im in g m a r ks
a lign ed (F ig. 88).
a n t t o t h e keywa y in t h e cr a n ksh a ft a n d in ser t t h e
key. Wit h t h e key in t h e keywa y on t h e cr a n ksh a ft ,
in st a ll t h e a ssem bly on t h e cr a n ksh a ft a n d ca m sh a ft .
(2) In st a ll t h e ca m sh a ft spr ocket bolt a n d wa sh er
(F ig. 89). Tigh t en t h e bolt t o 68 N·m (50 ft . lbs.)
t or qu e.
(3) To ver ify cor r ect in st a lla t ion of t h e t im in g
ch a in , r ot a t e t h e cr a n ksh a ft 2 r evolu t ion s. Th e ca m -
sh a ft a n d cr a n ksh a ft spr ocket t im in g m a r k sh ou ld
a lign (F ig. 88).
(4) In st a ll t h e cr a n ksh a ft oil slin ger.
(5) Repla ce t h e oil sea l in t h e t im in g ca se cover
(Refer t o 9 - E NGINE /E NGINE BLOCK/CRANK-
Fig. 89 Camshaft Sprocket and Thrust Plate SH AF T OIL SE AL - F RONT - RE MOVAL).
(6) In st a ll t h e t im in g ca se cover a n d ga sket (Refer
1 - CAMSHAFT
t o 9 - E NGINE /VALVE TIMING/TIMING BE LT /
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
CH AIN COVE R(S) - INSTALLATION).
4 - THRUST PLATE (7) Wit h t h e key in st a lled in t h e cr a n ksh a ft key-
wa y, in st a ll t h e vibr a t ion da m per (Refer t o 9 -
(9) Rem ove t h e cr a n ksh a ft spr ocket , ca m sh a ft INSTALLATION).
spr ocket a n d t im in g ch a in a s a n a ssem bly. (8) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
(10) In st a lla t ion of t h e t im in g ch a in wit h t h e t im - COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
in g m a r ks on t h e cr a n ksh a ft a n d ca m sh a ft spr ocket s INSTALLATION).
pr oper ly a lign ed en su r es cor r ect va lve t im in g. A wor n (9) In st a ll t h e fa n , h u b a ssem bly a n d sh r ou d
or st r et ch ed t im in g ch a in will a dver sely a ffect va lve (Refer t o 7 - COOLING/E NGINE /RADIATOR FAN -
t im in g. If t h e t im in g ch a in deflect s m or e t h a n 12.7 INSTALLATION).
m m (1/2 in ch ) r epla ce it . (10) Con n ect n ega t ive ca ble t o ba t t er y.
9 - 62 ENGINE 4.7L WJ
EN GI N E 4 .7 L
TABLE OF CONTENTS
page page
ENGINE 4.7L ROCKER ARM / ADJUSTER ASSEMBLY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 64 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ENGINE DIAGNOSIS - INTRODUCTION . . . . . . 64 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
SERVICE DIAGNOSIS - PERFORMANCE. . . . . 65 VALVE SPRINGS
SERVICE DIAGNOSIS - MECHANICAL . . . . . . . 67 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SERVICE DIAGNOSIS - LUBRICATION. . . . . . . 68 VALVE STEM SEALS
CYLINDER COMPRESSION PRESSURE TEST. . . 69 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CYLINDER COMBUSTION PRESSURE CYLINDER HEAD - RIGHT
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 70 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 70 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 96
REPAIR DAMAGED OR WORN THREADS . . . . 70 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 96
FORM-IN-PLACE GASKETS AND SEALERS. . . 70 HYDRAULIC LASH ADJUSTER NOISE
ENGINE GASKET SURFACE PREPARATION . . 71 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ENGINE CORE AND OIL GALLERY PLUGS . . . 72 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 74 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 75 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 78 CAMSHAFT(S) - RIGHT
AIR CLEANER ELEMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100
AIR CLEANER HOUSING CYLINDER HEAD COVER(S) - RIGHT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 82 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CYLINDER HEAD - LEFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 103
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . 83 INTAKE/EXHAUST VALVES & SEATS
HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS. . . 83 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . 83 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 104
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 REFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 85 ROCKER ARM / ADJUSTER ASSEMBLY
CAMSHAFT(S) - LEFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 89 VALVE SPRINGS
CYLINDER HEAD COVER(S) - LEFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 VALVE STEM SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 ENGINE BLOCK
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 92 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INTAKE/EXHAUST VALVES & SEATS STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 107
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 CYLINDER BORE HONING. . . . . . . . . . . . . . . 107
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 93 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
REFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 CONNECTING ROD BEARINGS
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 94 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 108
CONNECTING ROD BEARING FITTING . . . . . 108
WJ ENGINE 4.7L 9 - 63
CRANKSHAFT OIL FILTER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 110 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 110 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 131
CRANKSHAFT END PLAY. . . . . . . . . . . . . . . . 110 OIL PAN
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 111 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CRANKSHAFT MAIN BEARINGS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CRANKSHAFT MAIN BEARING-FITTING . . . . 114 OIL PRESSURE SENSOR/SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CRANKSHAFT OIL SEAL - FRONT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
CRANKSHAFT OIL SEAL - REAR OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 116 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . 133
FLEX PLATE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 117 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
PISTON & CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 135
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 117 INTAKE MANIFOLD
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 117 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 135
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 117 DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 136
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 INTAKE MANIFOLD LEAKAGE . . . . . . . . . . . . 136
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 119 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
PISTON RINGS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 137
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 120 EXHAUST MANIFOLD - LEFT
PISTON RING FITTING. . . . . . . . . . . . . . . . . . 120 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 137
VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 122 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
STRUCTURAL COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 138
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 123 EXHAUST MANIFOLD - RIGHT
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 123 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FRONT MOUNT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 124 VALVE TIMING
REAR MOUNT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 140
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 125 STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 142
LUBRICATION ENGINE TIMING - VERIFICATION . . . . . . . . . 142
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 126 MEASURING TIMING CHAIN WEAR . . . . . . . . 143
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 TIMING BELT / CHAIN COVER(S)
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 127 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
CHECKING ENGINE OIL PRESSURE . . . . . . . 127 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 146
REAR SEAL AREA LEAKS . . . . . . . . . . . . . . . 128 TIMING BELT/CHAIN AND SPROCKETS
ENGINE OIL LEAK INSPECTION . . . . . . . . . . 128 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 129
EN GI N E 4 .7 L
DESCRIPTION—4.7L ENGINE
Th e 4.7 lit er (287 CID) eigh t -cylin der en gin e is a n DIAGNOSIS AND TESTING—ENGINE
90° sin gle over h ea d ca m sh a ft en gin e. Th e ca st ir on
DIAGNOSIS - INTRODUCTION
cylin der block is m a de u p of t wo differ en t com po-
E n gin e dia gn osis is h elpfu l in det er m in in g t h e
n en t s; t h e fir st com pon en t is t h e cylin der bor e a n d
ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
u pper block, t h e secon d com pon en t is t h e bedpla t e
r ou t in e m a in t en a n ce.
t h a t com pr ises t h e lower por t ion of t h e cylin der block
Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er per-
a n d h ou ses t h e lower h a lf of t h e cr a n ksh a ft m a in
for m a n ce (e.g., en gin e idles r ou gh a n d st a lls) or
bea r in gs. Th e cylin der s a r e n u m ber ed fr om fr on t t o
m ech a n ica l (e.g., a st r a n ge n oise).
r ea r wit h t h e left ba n k bein g n u m ber ed 1,3,5 a n d 7,
a n d t h e r igh t ba n k bein g n u m ber ed 2,4,6 a n d 8. Th e
fir in g or der is 1–8–4–3–6–5–7–2. Th e en gin e ser ia l
n u m ber is loca t ed a t t h e r igh t fr on t side of t h e
en gin e block (F ig. 1)
EN GI N E 4 .7 L (Cont inue d)
DIAGNOSIS AND TE STING)—ME CH ANICAL for
possible ca u ses a n d cor r ect ion s of m a lfu n ct ion s.
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY -
DIAGNOSIS AND TE STING) a n d (Refer t o 14 -
F UE L SYSTE M/F UE L INJ E CTION - DIAGNOSIS
AND TE STING) for t h e fu el syst em dia gn osis.
Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
sis is pr ovided wit h in t h e followin g dia gn osis:
• Cylin der Com pr ession P r essu r e Test (Refer t o 9 -
E NGINE - DIAGNOSIS AND TE STING).
• Cylin der Com bu st ion P r essu r e Lea ka ge Test
ING).
• E n gin e Cylin der H ea d Ga sket F a ilu r e Dia gn osis
(Refer t o 9 - E NGINE /CYLINDE R H E AD - DIAGNO-
SIS AND TE STING).
• In t a ke Ma n ifold Lea ka ge Dia gn osis (Refer t o 9 -
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
DIAGNOSIS AND TE STING).
Fig. 1 Engine Identification Location
1 - VEHICLE VIN NUMBER LOCATION
2 - CYLINDER BLOCK RIGHT HAND SIDE
3 - CYLINDER BORE #2

ING)—P E RF ORMANCE a n d (Refer t o 9 - E NGINE -
DIAGNOSIS AND TESTING—SERVICE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.

2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Dirt or water in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture to lean or to rich. 2. Refer to Powertrain Diagnosis

Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
COIL - REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
1. Dirty or incorrectly gapped spark 1. (Refer to 8 - ELECTRICAL/

plugs. IGNITION CONTROL/SPARK PLUG
- CLEANING).
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), repair
as necessary.
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust 7. Inspect and replace as
system. necessary.
COIL - REMOVAL).
1. Spark plugs dirty or incorrectly 1. (Refer to 8 - ELECTRICAL/
gapped. IGNITION CONTROL/SPARK PLUG
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
COIL - REMOVAL).
1. Spark plugs dirty or incorrectly 1. (Refer to 8 - ELECTRICAL/

gapped. IGNITION CONTROL/SPARK PLUG
- CLEANING).
COIL - REMOVAL).
filter.
DIAGNOSIS AND TESTING—SERVICE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in 1. (Refer to LUBRICATION &

crankcase. MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Thin or diluted oil. 2. Change oil and filter.

3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
8. Excessive runout of valve seats 8. Service valves and valve seats.
on valve faces. (Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &

MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
wear.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal 5. Service or replace crankshaft.
out-of-round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
CONDITION POSSIBLE CAUSES CORRECTIONS
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &

MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
wear.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque 7. Tighten to correct torque
converter.
DIAGNOSIS AND TESTING—SERVICE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.

(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or (b) Tighten fasteners, Repair or
porous metal parts. replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange. 3. Polish or replace crankshaft.
Scratched, nicked or grooved.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal, 5. Replace seal (Refer to 9 -
damaged or misaligned. ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT
- REMOVAL).
6. Scratched or damaged vibration 6. Polish or replace damper.
damper hub.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9

- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pump suction tube loose or 9. Replace as necessary.
damaged.
OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone cylinder bores and replace
PLUGS FOULING rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
DIAGNOSIS AND TESTING—CYLINDER (2) Rem ove t h e spa r k plu gs.

(3) Secu r e t h e t h r ot t le in t h e wide-open posit ion .
COMPRESSION PRESSURE TEST
(4) Disa ble t h e fu el syst em (Refer t o 14 - F UE L
Th e r esu lt s of a cylin der com pr ession pr essu r e t est
SYSTE M/F UE L DE LIVE RY - DE SCRIP TION).
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c-
(5) Discon n ect t h e ign it ion coil.
t ion s.
(6) In ser t a com pr ession pr essu r e ga u ge a n d r ot a t e
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e
t h e en gin e wit h t h e en gin e st a r t er m ot or for t h r ee
en gin e st a r t er m ot or is in good oper a t in g con dit ion .
r evolu t ion s.
Ot h er wise t h e in dica t ed com pr ession pr essu r es m a y
(7) Recor d t h e com pr ession pr essu r e on t h e 3r d
n ot be va lid for dia gn osis pu r poses.
r evolu t ion . Con t in u e t h e t est for t h e r em a in in g cylin -
(1) Clea n t h e spa r k plu g r ecesses wit h com pr essed
der s.
a ir.
(Refer t o 9 - E NGINE - SP E CIF ICATIONS) for t h e (4) Rem ove t h e oil filler ca p.
cor r ect en gin e com pr ession pr essu r es. (5) Rem ove t h e a ir clea n er.
(6) Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa c-
DIAGNOSIS AND TESTING—CYLINDER t u r er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g
COMBUSTION PRESSURE LEAKAGE sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379
Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n kP a (200 psi) m a xim u m a n d 552 kP a (80 psi) r ecom -
a ccu r a t e m ea n s for det er m in in g en gin e con dit ion . m en ded.
Com bu st ion pr essu r e lea ka ge t est in g will det ect : (7) P er for m t h e t est pr ocedu r es on ea ch cylin der
• E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t - a ccor din g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s.
in g). Set pist on of cylin der t o be t est ed a t TDC com pr es-
• Lea ks bet ween a dja cen t cylin der s or in t o wa t er sion ,Wh ile t est in g, list en for pr essu r ized a ir esca pin g
ja cket . t h r ou gh t h e t h r ot t le body, t a ilpipe a n d oil filler ca p
• An y ca u ses for com bu st ion /com pr ession pr essu r e open in g. Ch eck for bu bbles in t h e r a dia t or coola n t .
loss. All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l,
(1) Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO wit h n o m or e t h a n 25% lea ka ge.
NOT in st a ll t h e r a dia t or ca p. F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es-
(2) St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in -
n or m a l oper a t in g t em per a t u r e, t h en t u r n t h e en gin e t a in ed in t h e cylin der.
OF F. Refer t o CYLINDE R COMBUSTION P RE SSURE
(3) Rem ove t h e spa r k plu gs. LE AKAGE DIAGNOSIS CH ART .
CY LI N DER COM BU ST I ON PRESSU RE LEAK AGE DI AGN OSI S CH ART

AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat.
THROTTLE BODY seated properly Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE seated properly Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE AND Stuck or broken piston rings; Inspect for broken rings or piston.
AIR ESCAPES THROUGH OIL cracked piston; worn rings and/or Measure ring gap and cylinder
FILLER CAP OPENING ONLY cylinder wall diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE—REPAIR DAMAGED • In st a llin g a n in ser t in t o t h e t a pped h ole t o br in g

t h e h ole ba ck t o it s or igin a l t h r ea d size.
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain STANDARD PROCEDURE—FORM-IN-PLACE
the original center line. GASKETS & SEALERS
Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce
Da m a ged or wor n t h r ea ds ca n be r epa ir ed. E ssen - ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
t ia lly, t h is r epa ir con sist s of: wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e
• Dr illin g ou t wor n or da m a ged t h r ea ds. obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in -
• Ta ppin g t h e h ole wit h a specia l H eli-Coil Ta p, or p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size,
equ iva len t . con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too
t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n ily be wiped off. Com pon en t s sh ou ld be t or qu ed in
r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel
flu id feed lin es. A con t in u ou s bea d of t h e pr oper is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r-
widt h is essen t ia l t o obt a in a lea k-fr ee ga sket . in g m a t er ia l off t h e loca t ion .
Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket
m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r ! m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d
E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r ! a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All
Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a
pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er. 3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e
MOPAR! EN GIN E RTV GEN II cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t
Mopa r ! E n gin e RTV GE N II is u sed t o sea l com - m a y be r em oved wit h a sh op t owel. Com pon en t s
pon en t s exposed t o en gin e oil. Th is m a t er ia l is a spe- sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill
cia lly design ed bla ck silicon e r u bber RTV t h a t wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a
r et a in s a dh esion a n d sea lin g pr oper t ies wh en loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e pr even t sm ea r in g m a t er ia l off t h e loca t ion .
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e a pplied u sin g a t h in , even coa t spr a yed com plet ely
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys over bot h su r fa ces t o be join ed, a n d bot h sides of a
in spect t h e pa cka ge for t h e expir a t ion da t e befor e ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a
u se. ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
MOPAR! ATF RTV sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be
Mopa r ! ATF RTV is a specifica lly design ed bla ck u sed on en gin es wit h m u lt i-la yer st eel ga sket s.
silicon e r u bber RTV t h a t r et a in s a dh esion a n d sea l-
in g pr oper t ies t o sea l com pon en t s exposed t o a u t o- STANDARD PROCEDURES - ENGINE GASKET
m a t ic t r a n sm ission flu id, en gin e coola n t s, a n d SURFACE PREPARATION
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
t h e pa cka ge for t h e expir a t ion da t e befor e u se. st eel cylin der h ea d ga sket s.
MOPAR! GAS KET MAKER N e v e r u se t h e followin g t o clea n ga sket su r fa ces:
Mopa r ! Ga sket Ma ker is a n a n a er obic t ype ga sket • Met a l scr a per
m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of a ir • Abr a sive pa d or pa per t o clea n cylin der block
wh en squ eezed bet ween t wo m et a llic su r fa ces. It will a n d h ea d
n ot cu r e if left in t h e u n cover ed t u be. Th e a n a er obic • H igh speed power t ool wit h a n a br a sive pa d or a
m a t er ia l is for u se bet ween t wo m a ch in ed su r fa ces. wir e br u sh (F ig. 2)
Do n ot u se on flexible m et a l fla n ges.
MOPAR! GAS KET S EALAN T NOTE: Multi-Layer Steel (MLS) head gaskets require
Mopa r ! Ga sket Sea la n t is a slow dr yin g, per m a - a scratch free sealing surface.
n en t ly soft sea ler. Th is m a t er ia l is r ecom m en ded for
sea lin g t h r ea ded fit t in gs a n d ga sket s a ga in st lea ka ge On ly u se t h e followin g for clea n in g ga sket su r fa ces:
of oil a n d coola n t . Ca n be u sed on t h r ea ded a n d • Solven t or a com m er cia lly a va ila ble ga sket
m a ch in ed pa r t s u n der a ll t em per a t u r es. Th is m a t e- r em over
r ia l is u sed on en gin es wit h m u lt i-la yer st eel (MLS) • P la st ic or wood scr a per (F ig. 2)
cylin der h ea d ga sket s. Th is m a t er ia l a lso will pr e- • Dr ill m ot or wit h 3M Roloc$ Br ist le Disc (wh it e
ven t cor r osion . Mopa r ! Ga sket Sea la n t is a va ila ble in or yellow) (F ig. 2)
a 13 oz. a er osol ca n or 4oz./16 oz. ca n w/a pplica t or.
CAUTION: Excessive pressure or high RPM (beyond
FORM-IN-PLACE GASKET AND SEALER the recommended speed), can damage the sealing
APPLICATION surfaces. The mild (white, 120 grit) bristle disc is
Assem blin g pa r t s u sin g a for m -in -pla ce ga sket recommended. If necessary, the medium (yellow, 80
r equ ir es ca r e bu t it ’s ea sier t h en u sin g pr ecu t ga s- grit) bristle disc may be used on cast iron surfaces
ket s. with care.
Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied
spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t
t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r-
r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s-
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Th or ou gh ly clea n in side of cu p plu g h ole in cylin -

der block or h ea d. Be su r e t o r em ove old sea ler.
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r !
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g
is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive
plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of
t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e
lea d-in ch a m fer.
It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t .
Th e coolin g syst em ca n be r efilled a n d t h e veh icle
pla ced in ser vice im m edia t ely.
REMOVAL
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(2) Rem ove t h e fr on t fa scia .
Fig. 2 PROPER TOOL USAGE FOR SURFACE (3) Ra ise veh icle on h oist .
PREPARATION (4) Rem ove exh a u st cr ossover pipe fr om exh a u st
1 - ABRASIVE PAD m a n ifolds.
2 - 3M ROLOC% BRISTLE DISC (5) Discon n ect t wo gr ou n d st r a ps fr om t h e lower
3 - PLASTIC/WOOD SCRAPER
left h a n d side a n d on e gr ou n d st r a p fr om t h e lower
r igh t h a n d side of t h e en gin e.
STANDARD PROCEDURE - ENGINE CORE AND (6) Discon n ect cr a n ksh a ft posit ion sen sor. (F ig. 4)
(7) Rem ove st r u ct u r a l cover (Refer t o 9 - E NGINE /
OIL GALLERY PLUGS E NGINE BLOCK/STRUCTURAL COVE R - RE MOV-
Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er, AL).
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p (8) Rem ove st a r t er. (Refer t o 8 - E LE CTRICAL/
plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it - STARTING/STARTE R MOTOR - RE MOVAL).
a ble t ool a n d r em ove plu g (F ig. 3). (9) Rem ove r u bber spla sh sh ield.
(10) Dr a in coolin g syst em (Refer t o 7 - COOLING -
(11) Rem ove t or qu e con ver t er bolt s.
(12) Rem ove t r a n sm ission t o en gin e m ou n t in g
bolt s.
(13) Discon n ect t h e en gin e block h ea t er power
ca ble fr om t h e block h ea t er.
(14) Lower veh icle.
(15) Rem ove t h r ot t le body r eson a t or a ssem bly a n d
in let h ose.
(16) Discon n ect t h r ot t le a n d speed con t r ol ca bles.
(17) Discon n ect t u be fr om bot h t h e left a n d r igh t
side cr a n kca se br ea t h er s, t h en r em ove t h e br ea t h er s
(F ig. 5).
(18) Disch a r ge A/C syst em (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/P LUMBING - STAN-
DARD P ROCE DURE ).
Fig. 3 CORE HOLE PLUG REMOVAL (19) Rem ove r a dia t or fa n (Refer t o 7 - COOLING/
1 - CYLINDER BLOCK E NGINE /RADIATOR FAN - RE MOVAL) a n d a cces-
2 - REMOVE PLUG WITH PLIERS sor y dr ive belt (Refer t o 7 - COOLING/ACCE SSORY
3 - STRIKE HERE WITH HAMMER DRIVE /DRIVE BE LTS - RE MOVAL).
4 - DRIFT PUNCH
(20) Rem ove A/C com pr essor (Refer t o 24 - H E AT-
5 - CUP PLUG
ING & AIR CONDITIONING/P LUMBING/A/C COM-
P RE SSOR - RE MOVAL).
(26) Discon n ect t h e t wo h ea t er h oses fr om t h e t im -
in g ch a in cover.
(27) Discon n ect en gin e h a r n ess a t t h e followin g
poin t s :
• In t a ke a ir t em per a t u r e (IAT) sen sor (F ig. 6)
• F u el In ject or s
• Th r ot t le P osit ion (TP S) Swit ch
• Idle Air Con t r ol (IAC) Mot or
• E n gin e Oil P r essu r e Swit ch
• E n gin e Coola n t Tem per a t u r e (E CT) Sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) Sen sor
• Ca m sh a ft P osit ion (CMP ) Sen sor
• Coil Over P lu gs
Fig. 4 Crankshaft Position Sensor

1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
Fig. 5 Crankcase Breather Connection Points Fig. 6 Throttle Body Connection Points
1 - CRANKCASE BREATHERS 1 - THROTTLE BODY
2 - TPS
(21) Discon n ect t r a n sm ission oil cooler lin es a t t h e 3 - IAC MOTOR
4 - IAT SENSOR
r a dia t or.
5 - MOUNTING SCREWS
(22) Discon n ect r a dia t or lower h ose a t t h e t h er m o-
st a t h ou sin g.
(23) Rem ove A/C con den ser (Refer t o 24 - H E AT- (28) Relea se fu el r a il pr essu r e (Refer t o 14 - F UE L
ING & AIR CONDITIONING/P LUMBING/A/C CON- SYSTE M/F UE L DE LIVE RY - STANDARD P ROCE -
DE NSE R - RE MOVAL). DURE ) t h en discon n ect t h e fu el su pply qu ick con n ect
(24) Rem ove r a dia t or (Refer t o 7 - COOLING/E N- fit t in g a t t h e fu el r a il (Refer t o 14 - F UE L SYSTE M/
GINE /RADIATOR - RE MOVAL). F UE L DE LIVE RY/QUICK CONNE CT F ITTING -
(25) Rem ove gen er a t or (Refer t o 8 - E LE CTRICAL/ STANDARD P ROCE DURE ).
CH ARGING/GE NE RATOR - RE MOVAL). (29) Rem ove power st eer in g pu m p a n d posit ion ou t
of t h e wa y.
(30) Discon n ect gr ou n d st r a ps fr om t h e left side of NOTE: It will be necessary to support the transmis-
t h e en gin e. sion in order to remove the engine.
(31) In st a ll E n gin e Lift in g F ixt u r e Specia l Tool
8347 (F ig. 7)followin g t h ese st eps. (33) P osit ion a su it a ble ja ck u n der t h e t r a n sm is-
• H oldin g t h e lift in g fixt u r e a t a sligh t a n gle, slide sion .
t h e la r ge bor e in t h e fr on t pla t e over t h e h ex por t ion (34) Rem ove t h e en gin e m ou n t t h r ou gh bolt s.
of t h e lift in g st u d. (35) Ra ise en gin e sligh t ly, t h en r em ove bot h left
• P osit ion t h e t wo r em a in in g fixt u r e a r m s on t o a n d r igh t side en gin e m ou n t s fr om en gin e. (Refer t o
t h e t wo lift in g st u ds in t h e cylin der h ea ds. 9 - E NGINE /E NGINE MOUNTING/F RONT MOUNT
• P u ll fowa r d a n d u pwa r d on t h e lift in g fixt u r e so - RE MOVAL).
t h a t t h e lift in g st u d r est in t h e slot t ed a r ea below t h e (36) Rem ove en gin e fr om t h e veh icle.
la r ge bor e.
• Secu r e t h e lift in g fixt u r e t o t h e t h r ee st u ds INSTALLATION
u sin g t h r ee 7/16 – 14 N/C lockn u t s. (1) P osit ion en gin e in t h e veh icle.
• Ma ke su r e t h e lift in g loop in t h e lift in g fixt u r e is (2) In st a ll bot h left a n d r igh t side en gin e m ou n t s
in t h e la st h ole (closest t o t h e t h r ot t le body) t o m in - on t o en gin e (Refer t o 9 - E NGINE /E NGINE MOUNT-
im ize t h e a n gle of en gin e du r in g r em ova l. ING/F RONT MOUNT - INSTALLATION).
(3) In st a ll t r a n sm ission t o en gin e m ou n t in g bolt s.
Tigh t en t h e bolt s t o 41 N·m (30 ft . lbs.).
(4) Rem ove ja ck fr om u n der t h e t r a n sm ission .
(5) Rem ove en gin e lift in g fixt u r e specia l t ool 8347
(F ig. 7).
(6) Con n ect gr ou n d st r a ps on t h e left side of t h e
en gin e.
(7) In st a ll power st eer in g pu m p (Refer t o 19 -
STE E RING/P UMP - INSTALLATION).
(8) Con n ect fu el su pply lin e qu ick con n ect fit t in g
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/
QUICK CONNE CT F ITTING - STANDARD P ROCE -
DURE ).
(9) Con n ect en gin e h a r n ess a t t h e followin g poin t s
(F ig. 6):
• In t a ke Air Tem per a t u r e (IAT) Sen sor
• F u el In ject or s
• Th r ot t le P osit ion (TP S) Swit ch
• E n gin e Oil P r essu r e Swit ch
• E n gin e Coola n t Tem per a t u r e (E CT) Sen sor
• Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor
• Ca m sh a ft P osit ion (CMP ) Sen sor
• Coil Over P lu gs
(10) In st a ll gen er a t or (Refer t o 8 - E LE CTRICAL/
CH ARGING/GE NE RATOR - INSTALLATION).
(11) In st a ll r a dia t or (Refer t o 7 - COOLING/E N-
GINE /RADIATOR - INSTALLATION).
(12) In st a ll A/C con den ser (Refer t o 24 - H E ATING
& AIR CONDITIONING/P LUMBING/A/C CON-
DE NSE R - INSTALLATION).
Fig. 7 Engine Lifting Fixture Attachment Locations (13) Con n ect r a dia t or lower h ose a t t h e t h er m ost a t
1 - ATTACHING LOCATION h ou sin g.
2 - ADJUSTABLE HOOK (14) Con n ect t h e t r a n sm ission oil cooler lin es t o
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE t h e r a dia t or.
4 - ATTACHING LOCATIONS (15) In st a ll A/C com pr essor. (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/P LUMBING/A/C COM-
(32) Discon n ect body gr ou n d st r a p a t t h e r igh t side P RE SSOR - INSTALLATION).
cowl.
(16) In st a ll a ccessor y dr ive belt (Refer t o 7 - COOL-
DESCRIPTION SPECIFICATION
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTALLA-
TION) a n d r a dia t or fa n (Refer t o 7 - COOLING/ Horsepower 235 BHP @ 4800 RPM
E NGINE /RADIATOR FAN - INSTALLATION). Torque 295 LB-FT @ 3200 RPM
(17) In st a ll br ea t h er s, t h en con n ect t u be t o bot h Lead Cylinder #1 Left Bank
cr a n kca se br ea t h er s (F ig. 5).
(18) Con n ect t h r ot t le a n d speed con t r ol ca bles. Firing Order 1-8-4-3-6-5-7-2
(19) In st a ll t h r ot t le body r eson a t or a ssem bly a n d CYLINDER BLOCK
in let h ose.
Cylinder Block Cast Iron
(20) Ra ise veh icle.
(21) Con n ect t wo gr ou n d st r a ps on t h e lower left Bore Diameter 93.010 " .0075 mm
h a n d side of t h e en gin e a n d on e gr ou n d st r a p on t h e (3.6619 " 0.0003 in.)
lower r igh t side. Out of Round (MAX) 0.076 mm (0.003 in.)
(22) In st a ll t or qu e con ver t er bolt s.
(23) Con n ect cr a n ksh a ft posit ion sen sor (F ig. 4). Taper (MAX) 0.051 mm (0.002 in.)
(24) In st a ll st a r t er. PISTONS
(25) In st a ll r u bber spla sh sh ield.
Material Aluminum Alloy
CAUTION: The structural cover requires a specific Diameter 92.975 mm (3.6605 in.)
torque sequence. Failure to follow this sequence Weight 367.5 grams (12.96 oz)
may cause severe damage to the cover.
Ring Groove Diameter
(26) In st a ll st r u ct u r a l cover (Refer t o 9 - E NGINE / No. 1 83.73 - 83.97 mm
E NGINE BLOCK/STRUCTURAL COVE R - INSTAL-
(3.296 - 3.269 in.)
LATION).
(27) In st a ll exh a u st cr ossover pipe. No. 2 82.833 - 83.033 mm
(28) In st a ll en gin e block h ea t er power ca ble, If (3.261 - 3.310 in.)
equ ipped.
(29) Lower veh icle. No. 3 83.88 - 84.08 mm
(30) Ch eck a n d fill en gin e oil (Refer t o LUBRICA- (3.302 - 3.310 in.)
TION & MAINTE NANCE /F LUID TYP E S - SP E CIF I-
PISTON PINS
CATIONS).
(31) Rech a r ge t h e A/C syst em (Refer t o 24 - H E AT- Type Pressed Fit
ING & AIR CONDITIONING/P LUMBING - STAN- Clearance In Piston 0.010 - 0.019 mm
DARD P ROCE DURE ).
(0.0004 - 0.0008 in.)
(32) Refill t h e en gin e coolin g syst em (Refer t o 7 -
COOLING - STANDARD P ROCE DURE ). Diameter 24.013 - 24.016 mm
(33) Con n ect t h e ba t t er y n ega t ive ca ble. (0.9454 - 0.9456 in.)
(34) St a r t en gin e a n d ch eck for lea ks.
PISTON RINGS
Ring Gap
SPECI FI CAT I ON S
Top Compression Ring 0.37 - 0.63 mm
4.7L ENGINE (0.0146 - 0.0249 in.)
Second Compression 0.37 - 0.63 mm
DESCRIPTION SPECIFICATION Ring
GENERAL SPECIFICATIONS (0.0146 - 0.0249 in.)
Engine Type 90° SOHC V-8 16-Valve Oil Control (Steel Rails) 0.25 - 0.76 mm
Displacement 4.7 Liters / 4701cc (0.0099 - 0.30 in.)
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Compression Ratio 9.0:1

Side Clearance Connecting Rod
Top Compression Ring .051 - .094 mm Journal
(0.0020 - 0.0037 in.) Diameter 50.992 - 51.008 mm
Second Compression 0.040 - 0.080 mm (2.0076 - 2.0082 in.)

Ring Bearing Clearance 0.015 - 0.055 mm
(0.0016 - 0.0031 in.) (0.0006 -0.0022 in.)
Oil Ring (Steel Ring) .019 - .229 mm Out of Round (MAX) 0.005 mm (0.0002 in.)
(.0007 - .0091 in.) Taper (MAX) 0.008 mm (0.0004 in.)
Ring Width CAMSHAFT

Top Compression Ring 1.472 - 1.490 mm Bore Diameter 26.02 - 26.04 mm
(1.0245 - 1.0252 in.)
(0.057 - 0.058 in.)
Bearing Journal Diameter 25.975 - 25.995 mm
Second Compression 1.472 - 1.490 mm
Ring (1.0227 - 1.0235 in.)
(0.057 - 0.058 in.) Bearing Clearance 0.025 - 0.065 mm
Oil Ring (Steel Rails) 0.445 - 0.470 mm (0.001 - 0.0026 in.)
(0.017 - 0.018 in.) Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
End Play .075 - .200 mm
CONNECTING RODS
Bearing Clearance 0.010 - 0.048 mm (0.003 - 0.0079 in.)
End Play (MAX) .200 mm (0.0079 in.)
(0.0004 - 0.0019 in.)
Side Clearance 0.10 - 0.35 mm VALVE TIMING
(0.004 - 0.0138 in.) Intake
Piston Pin Bore Diameter .022 - .045 mm Opens (ATDC) 3.6°
(Interference Fit) (0.0009 - 0.0018 in.) Closes (ATDC) 247.1°
Bearing Bore Out of 0.004 mm Duration 243.5°
Round
Exhaust
(MAX) (0.0002 in.) Opens (BTDC) 232.5°
Total Weight (Less 555 grams (19.5771 Closes (ATDC) 21.2°
Bearing) ounces)
Duration 253.70°
CRANKSHAFT
Valve Overlap 17.6°
Main Bearing Journal
VALVES
Diameter 63.488 - 63.512 mm Face Angle 45° - 45.5°
(2.4996 - 2.5005 in.)
Head Diameter
Bearing Clearance 0.018 - 0.052 mm
Intake 48.52 - 48.78 mm
(0.0008 - 0.0021 in.)
(1.9103 - 1.9205 in.)
Out of Round (MAX) 0.005 mm (0.0002 in.)
Exhaust 36.87 - 37.13 mm
Taper (MAX) 0.008 mm (0.0004 in.)
1.4516 - 1.4618 in.)
End Play 0.052 - 0.282 mm
(0.0021 - 0.0112 in.)
End Play (MAX) 0.282 mm (0.0112 in)

Length (Overall) Wire Diameter
Intake 113.45 - 114.21 mm Intake and Exhaust 4.2799 - 4.3561 mm
(4.4666 - 4.4965) (0.1685 - 0.1715 in.)
Exhaust 114.92 - 115.68 mm Installed Height (Spring
(4.5244 - 4.5543 in.) Seat to Bottom of
Stem Diameter Retainer)
Intake 6.931 - 6.957 mm Nominal
(0.2729 - 0.2739 in.) Intake 40.97 mm (1.613 in.)
Exhaust 6.902 - 6.928 mm Exhaust 40.81 mm (1.606 in.)
(0.2717 - 0.2728 in.) CYLINDER HEAD
Stem - to - Guide Gasket Thickness
Clearance (Compressed) .7 mm (0.0276 in.)
Intake .018 - .069 mm Valve Seat Angle 44.5° - 45.0°
(0.0008 - 0.0028 in.) Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Exhaust .047 - .098 mm Valve Seat Width
(0.0019 - 0.0039 in.) Intake 1.75 - 2.36 mm
Max. Allowable Stem - (0.0698 - 0.0928 in.)
to - Guide Clearance
Exhaust 1.71 - 2.32 mm
(Rocking Method)
(0.0673 - 0.0911 in.)
Intake 0.069 mm (0.0028 in.)
Guide Bore Diameter 6.975 - 7.00 mm
Exhaust 0.098 mm (0.0039 in.)
(Std.)
Valve Lift (Zero Lash) (0.2747 - 0.2756 in.)
Intake 11.25 mm (0.443 in.) Cylinder Head Warpage
Exhaust 10.90 mm (0.4292 in.) (Flatness) 0.0508 mm (0.002 in.)
VALVE SPRING OIL PUMP
Free Length (Approx) Clearance Over Rotors .035 - .095 mm
Intake and Exhaust 48.6 mm (1.9134 in.) (MAX)
Spring Force (Valve (0.0014 - 0.0038 in.)
Closed) Cover Out - of -Flat .025 mm (0.001 in.)
(MAX)
Intake and Exhaust 315.5 - 352.5 N @ 40.89
mm Inner and Outer Rotor
(70.92722 - 79.24515 lbs. Thickness 12.08 mm (0.4756 in.)
@ 1.6099 in.) Outer Rotor Clearance 85.96 mm (3.3843 in.)
Spring Force (Valve (MAX)
Open) Outer Rotor Diameter 85.925 mm (0.400 in.)
(MIN)
Intake and Exhaust 786.0 - 860.0 N @ 29.64
mm Tip Clearance Between
Rotors
176.6998 - 193.3357 lbs.
@ 1.167 in.) (MAX) .150 mm (0.006 in.)
Number of Coils
Intake and Exhaust 6.69
DESCRIPTION SPECIFICATION DESCRIPTION N·m Ft. In.

OIL PRESSURE Lbs. Lbs.
At Curb Idle Speed 25 kPa (4 psi) Oil Pan—Drain Plug 34 25 —
(MIN)* Oil Pump—Bolts 28 — 250
@ 3000 rpm 170 - 550 kPa (25 - 80 Oil Pump Cover—Bolts 12 — 105
psi)
Oil Pickup Tube—Bolt and 28 — 250
* CAUTION: If pressure is zero at curb idle, DO Nut
NOT run
Oil Dipstick Tube to Engine
engine at 3000 rpm. Block—Bolt 15 — 130
Oil Fill Tube—Bolts 12 — 105
TORQUE
Timing Chain Guide—Bolts 28 — 250
Timing Chain Tensioner
DESCRIPTION N·m Ft. In. Arm—Special
Lbs. Lbs. Pin Bolt 17 — 150
Camshaft Hydraulic Tensioner—Bolts 28 — 250
Non - Oiled Sprocket Bolt 122 90 — Timing Chain Primary 28 — 250
Bearing Cap Bolts 11 — 100 Tensioner—Bolts
Timing Chain Cover—Bolts 54 40 — Timing Drive Idler Sprocket— 34 25 —
Bolt
Connecting Rod Cap—Bolts 27 20 —
Thermostat Housing—Bolts 13 — 115
PLUS 90° TURN
Water Pump—Bolts 54 40 —
Bed Plate—Bolts Refer to Procedure
Crankshaft Damper—Bolt 175 130 —
SPECI AL T OOLS
Cylinder Head—Bolts
M11 Bolts 81 60 — 4.7L ENGINE
M8 Bolts 26 19 —
Cylinder Head Cover—Bolts 12 — 105
Exhaust Manifold—Bolts 25 18 —
Exhaust Manifold Heat 8 — 72
Shield—Nuts
Then loosen 45°
Flexplate—Bolts 60 45 —
Engine Mount Bracket to 61 45 — Spanner Wrench 6958
Block—Bolts
Rear Mount to 46 34 —
Transmission—Bolts
Generator Mounting—Bolts
M10 Bolts 54 40 —
M8 Bolts 28 — 250
Intake Manifold—Bolts 12 — 105
Refer to Procedure
for
Tightening Sequence
Oil Pan—Bolts 15 — 130 Adapter Pins 8346
SPECI AL T OOLS (Cont inue d)
Engine Lifting Studs 8400
Handle C-4171
Engine Lift Fixture 8347
Rear Crankshaft Seal Installer 8349
Front Crankshaft Seal Remover 8511
Rear Crankshaft Seal Remover 8506
Front Crankshaft Seal Installer 8348
Connecting Rod Guides 8507

Crankshaft Damper Installer 8512

Chain Tensioner Pins 8514
Puller 1026
Secondary Chain Holder 8515
Crankshaft Damper Removal Insert 8513
Remover, Rocker Arm 8516
Chain Tensioner
Valve Spring Compressor 8387

Bore Size Indicator C-119
Idler Shaft Remover 8517
Oil Pressure Gauge C-3292
Valve Spring Compressor Adapters 8519
Piston Ring Compressor C-385
Valve Spring Tester C-647
Pressure Tester Kit 7700
Dial Indicator C-3339
Bloc–Chek–Kit C-3685–A
Valve Spring Compressor C-3422-B

AI R CLEAN ER ELEM EN T AI R CLEAN ER H OU SI N G

REMOVAL - 4.7L REMOVAL - 4.7L
(1) Un la t ch fou r clips r et a in in g a ir clea n er cover t o (1) Discon n ect a ir clea n er cover-t o-a ir du ct cla m p
a ir clea n er h ou sin g (F ig. 8). (F ig. 8).
(2) Discon n ect a ir du ct a t h ou sin g.
(3) Ea c h o f th e 3 a ir c le a n e r h o u s in g m o u n t-
in g bo lts is a tta c h e d w ith 2 n u ts (a n u p p e r n u t
a n d lo w e r n u t). D O N OT REMOVE B OLTS . To
p re v e n t s trip p in g bo lts , o n ly re m o v e lo w e r
n u ts . Th e lo w e r h o u s in g n u ts a re lo c a te d u n d e r
le ft fro n t in n e r fe n d e r (F ig . 8).
(a ) To ga in a ccess t o lower n u t s, r a ise veh icle.
(b) Rem ove clips r et a in in g r u bber in n er fen der
sh ield.
(c) P r y ba ck sh ield en ou gh t o ga in a ccess t o
lower n u t s.
(d) Rem ove 3 n u t s.
(e) Rem ove a ir clea n er a ssem bly fr om veh icle.
(4) If r eson a t or is t o be r em oved, discon n ect
br ea t h er t u be a t r eson a t or, discon n ect a ir du ct cla m p
a t r eson a t or (F ig. 8)a n d r em ove 2 r eson a t or m ou n t -
in g bolt s (a t sides of r eson a t or ). Rem ove r eson a t or
fr om t h r ot t le body by loosen in g cla m p a t t h r ot t le
body.
INSTALLATION - 4.7L
(1) P osit ion a ir clea n er a ssem bly t o body a n d
in st a ll 3 n u t s. Tigh t en n u t s t o 10 N·m (93 in . lbs.)
t or qu e. To p re v e n t e x c e s s iv e v ibra tio n tra n s m it-
te d th ro u g h h o u s in g , th e n u ts m u s t be p ro p e rly
to rqu e d . D o n o t o v e rtig h te n n u ts .
Fig. 8 Air Cleaner Assembly - 4.7L (2) If r eson a t or wa s r em oved: In st a ll r eson a t or a n d
bolt s. Tigh t en bolt s t o 4 N·m (35 in . lbs.) t or qu e.
1 - AIR DUCT
Tigh t en cla m p a t t h r ot t le body t o 4 N·m (35 in . lbs.)
2 - CLAMPS
3 - AIR CLEANER COVER
t or qu e.
4 - CLIPS (3) P osit ion fen der lin er a n d in st a ll clips.
5 - HOUSING (4) Con n ect a ir du ct a t h ou sin g (F ig. 8).
6 - HOUSING BOLTS (3) (5) Tigh t en a ir du ct cla m p.
7 - LOWER HOUSING NUTS (3)
8 - RESONATOR BOLTS
9 - RESONATOR CY LI N DER H EAD - LEFT
(2) Lift cover u p a n d posit ion t o t h e side. DESCRIPTION—CYLINDER HEAD
(3) Rem ove a ir clea n er elem en t . Th e cylin der h ea ds a r e m a de of a n a lu m in u m a lloy.
Th e cylin der h ea d fea t u r es t wo va lves per cylin der
INSTALLATION - 4.7L wit h pr essed in powder ed m et a l va lve gu ides. Th e
(1) Clea n in side of a ir clea n er h ou sin g befor e cylin der h ea ds a lso pr ovide en closu r es for t h e t im in g
in st a llin g n ew elem en t . ch a in dr a in , n ecessit a t in g u n iqu e left a n d r igh t cylin -
(2) In st a ll a ir clea n er elem en t in t o h ou sin g. der h ea ds.
(3) La t ch clips a n d cla m p cover down t o secu r e. Be
su r e a ir clea n er cover is pr oper ly sea t ed t o a ir DESCRIPTION—VALVE GUIDES
clea n er h ou sin g. Th e va lve gu ides a r e m a de of power ed m et a l a n d
a r e pr essed in t o t h e cylin der h ea d. Th e gu ides a r e
n ot r epla cea ble or ser vicea ble, a n d va lve gu ide r ea m -
CY LI N DER H EAD - LEFT (Cont inue d)
in g is n ot r ecom m en ded. If t h e gu ides a r e wor n CYLINDER-TO-CYLINDER LEAKAGE TEST
beyon d a ccept a ble lim it s, r epla ce t h e cylin der h ea ds. To det er m in e if a n en gin e cylin der h ea d ga sket is
lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce-
DIAGNOSIS AND TESTING—HYDRAULIC LASH du r es in Cylin der Com pr ession P r essu r e Test (Refer
ADJUSTER NOISE DIAGNOSIS t o 9 - E NGINE - DIAGNOSIS AND TE STING). An
A t a ppet -like n oise m a y be pr odu ced fr om sever a l en gin e cylin der h ea d ga sket lea kin g bet ween a dja -
it em s. Ch eck t h e followin g it em s. cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70%
(1) E n gin e oil level t oo h igh or t oo low. Th is m a y r edu ct ion in com pr ession pr essu r e.
ca u se a er a t ed oil t o en t er t h e a dju st er s a n d ca u se
t h em t o be spon gy. CYLINDER-TO-WATER JACKET LEAKAGE TEST
(2) In su fficien t r u n n in g t im e a ft er r ebu ildin g cylin -
der h ea d. Low speed r u n n in g u p t o 1 h ou r m a y be WARNING: USE EXTREME CAUTION WHEN THE
r equ ir ed. ENGINE IS OPERATING WITH COOLANT PRES-
(3) Tu r n en gin e off a n d let set for a few m in u t es SURE CAP REMOVED.
befor e r est a r t in g. Repea t t h is sever a l t im es a ft er
en gin e h a s r ea ch ed n or m a l oper a t in g t em per a t u r e. VISUAL TEST METHOD
(4) Low oil pr essu r e.
Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e
(5) Th e oil r est r ict or in cylin der h ea d ga sket or t h e
ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il
oil pa ssa ge t o t h e cylin der h ea d is plu gged wit h
t h er m ost a t open s.
debr is.
If a la r ge com bu st ion /com pr ession pr essu r e lea k
(6) Air in gest ed in t o oil du e t o br oken or cr a cked
exist s, bu bbles will be visible in t h e coola n t .
oil pu m p pick u p.
(7) Wor n va lve gu ides. COOLING SYSTEM TESTER METHOD
(8) Rocker a r m ea r s con t a ct in g va lve spr in g
r et a in er. WARNING: WITH COOLING SYSTEM TESTER IN
(9) Rocker a r m loose, a dju st er st u ck or a t m a xi- PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
m u m ext en sion a n d st ill lea ves la sh in t h e syst em . SIVE PRESSURE BUILT UP, BY CONTINUOUS
(10) F a u lt y la sh a dju st er. ENGINE OPERATION, MUST BE RELEASED TO A
• Ch eck la sh a dju st er s for spon gin ess wh ile SAFE PRESSURE POINT. NEVER PERMIT PRES-
in st a lled in cylin der h ea d a n d ca m on ca m sh a ft a t SURE TO EXCEED 138 kPa (20 psi).
ba se cir cle. Depr ess pa r t of r ocker a r m over a dju st er.
Nor m a l a dju st er s sh ou ld feel ver y fir m . Spon gy In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o
a dju st er s ca n be bot t om ed ou t ea sily. pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e
• Rem ove su spect ed la sh a dju st er s, a n d r epla ce. t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y
• Befor e in st a lla t ion , m a ke su r e a dju st er s a r e a t power st r oke of a cylin der a com bu st ion pr essu r e
lea st pa r t ia lly fu ll of oil. Th is ca n be ver ified by lit t le lea k is eviden t .
or n o plu n ger t r a vel wh en la sh a dju st er is depr essed.
CHEMICAL TEST METHOD
DIAGNOSIS AND TESTING—CYLINDER HEAD Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso
GASKET be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or
A cylin der h ea d ga sket lea k ca n be loca t ed bet ween equ iva len t . P er for m t est followin g t h e pr ocedu r es
a dja cen t cylin der s or bet ween a cylin der a n d t h e su pplied wit h t h e t ool kit .
a dja cen t wa t er ja cket .
P ossible in dica t ion s of t h e cylin der h ea d ga sket REMOVAL
lea kin g bet ween a dja cen t cylin der s a r e: (1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.
• Loss of en gin e power (2) Ra ise t h e veh icle on a h oist .
• E n gin e m isfir in g (3) Discon n ect t h e exh a u st pipe a t t h e left side
• P oor fu el econ om y exh a u st m a n ifold.
P ossible in dica t ion s of t h e cylin der h ea d ga sket (4) Dr a in t h e en gin e coola n t . (Refer t o 7 - COOL-
lea kin g bet ween a cylin der a n d a n a dja cen t wa t er ING - STANDARD P ROCE DURE ).
ja cket a r e: (5) Lower t h e veh icle.
• E n gin e over h ea t in g (6) Rem ove t h e in t a ke m a n ifold. (Refer t o 9 -
• Loss of coola n t E NGINE /MANIF OLDS/INTAKE MANIF OLD -
• E xcessive st ea m (wh it e sm oke) em it t in g fr om RE MOVAL).
exh a u st
• Coola n t foa m in g
(7) Rem ove t h e cylin der h ea d cover. (Refer t o 9 -
(8) Rem ove a ccessor y dr ive belt . (Refer t o 7 -
RE MOVAL).
(9) Rem ove t h e power st eer in g pu m p a n d set
a side.
(10) Rot a t e t h e cr a n ksh a ft u n t il t h e da m per t im -
in g m a r k is a lign ed wit h TDC in dica t or m a r k (F ig.
9).
Fig. 10 Using Special Tool 8515 to Hold Chains to

Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
6 - SPECIAL TOOL 8515
(16) Rem ove t h e left side secon da r y ch a in t en -

sion er. (Refer t o 9 - E NGINE /VALVE TIMING/TIM-
ING BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
(17) Rem ove t h e cylin der h ea d a ccess plu g (F ig.
12).
(18) Rem ove t h e left side secon da r y ch a in gu ide.
Fig. 9 Engine Top Dead Center
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
1 - TIMING CHAIN COVER
BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
2 - CRANKSHAFT TIMING MARKS
(19) Rem ove t h e r et a in in g bolt a n d t h e ca m sh a ft
dr ive gea r.
(11) Ver ify t h e V8 m a r k on t h e ca m sh a ft spr ocket
is a t t h e 12 o’clock posit ion (F ig. 11). Rot a t e t h e CAUTION: Do not allow the engine to rotate. Severe
cr a n ksh a ft on e t u r n if n ecessa r y. damage to the valve train can occur.
(12) Rem ove t h e cr a n ksh a ft da m per. (Refer t o 9 -
CAUTION: Do not overlook the four smaller bolts at
RE MOVAL).
the front of the cylinder head. Do not attempt to
(13) Rem ove t h e t im in g ch a in cover. (Refer t o 9 -
remove the cylinder head without removing these
four bolts.
(14) Lock t h e secon da r y t im in g ch a in s t o t h e idler
spr ocket u sin g Specia l Tool 8515 (F ig. 10). NOTE: The cylinder head is attached to the cylinder
block with fourteen bolts.
NOTE: Mark the secondary timing chain prior to
removal to aid in installation. (20) Rem ove t h e cylin der h ea d r et a in in g bolt s.
(21) Rem ove t h e cylin der h ea d a n d ga sket . Disca r d
(15) Ma r k t h e secon da r y t im in g ch a in , on e lin k on t h e ga sket .
ea ch side of t h e V8 m a r k on t h e ca m sh a ft dr ive gea r
(F ig. 11).
Fig. 11 Camshaft Sprocket V8 Marks

1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
CLEANING
To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s. (Refer t o 9 -
E NGINE - STANDARD P ROCE DURE )
INSPECTION
(1) In spect t h e cylin der h ea d for ou t -of-fla t n ess,
u sin g a st r a igh t edge a n d a feeler ga u ge. If t oler a n ces
exceed 0.0508 m m (0.002 in .) r epla ce t h e cylin der
h ea d.
(2) In spect t h e va lve sea t s for da m a ge. Ser vice t h e
va lve sea t s a s n ecessa r y.
(3) In spect t h e va lve gu ides for wea r, cr a cks or
loosen ess. If eit h er con dit ion exist , r epla ce t h e cylin -
Fig. 12 Cylinder Head Access Plugs der h ea d.
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG INSTALLATION
NOTE: The cylinder head bolts are tightened using
CAUTION: Do not lay the cylinder head on its gas- a torque plus angle procedure. The bolts must be
ket sealing surface, due to the design of the cylin- examined BEFORE reuse. If the threads are necked
der head gasket any distortion to the cylinder head down the bolts should be replaced.
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks. Neckin g ca n be ch ecked by h oldin g a st r a igh t edge
a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds do n ot con t a ct
t h e sca le, t h e bolt sh ou ld be r epla ced (F ig. 13).
Fig. 13 Checking Cylinder Head Bolts for Stretching

(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE Fig. 14 Cylinder Head Tightening Sequence
3 - THREADS ARE STRAIGHT ON LINE
(7) In st a ll t h e secon da r y ch a in a n d secon da r y
4 - UNSTRETCHED BOLT
ch a in gu ide (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS -
CAUTION: When cleaning cylinder head and cylin- INSTALLATION).
der block surfaces, DO NOT use a metal scraper (8) In st a ll t h e cylin der h ea d a ccess plu g.
because the surfaces could be cut or ground. Use (9) Re-set a n d In st a ll t h e left side secon da r y ch a in
only a wooden or plastic scraper. t en sion er (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS -
(1) Clea n t h e cylin der h ea d a n d cylin der block INSTALLATION).
m a t in g su r fa ces (Refer t o 9 - E NGINE - STANDARD (10) Rem ove Specia l Tool 8515.
P ROCE DURE ). (11) In st a ll t h e t im in g ch a in cover (Refer t o 9 -
(2) P osit ion t h e n ew cylin der h ea d ga sket on t h e E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
loca t in g dowels. COVE R(S) - INSTALLATION).
(12) In st a ll t h e cr a n ksh a ft da m per (Refer t o 9 -
CAUTION: When installing cylinder head, use care E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
not damage the tensioner arm or the guide arm. INSTALLATION).
(13) In st a ll t h e power st eer in g pu m p.
(3) P osit ion t h e cylin der h ea d on t o t h e cylin der
(14) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
block. Ma ke su r e t h e cylin der h ea d sea t s fu lly over
t h e loca t in g dowels.
NOTE: The four smaller cylinder head mounting (15) In st a ll t h e in t a ke m a n ifold (Refer t o 9 -
bolts require sealant to be added to them before E NGINE /MANIF OLDS/INTAKE MANIF OLD -
installing. Failure to do so may cause leaks. INSTALLATION).
(16) Refill t h e coolin g syst em (Refer t o 7 - COOL-
(4) Lu br ica t e t h e cylin der h ea d bolt t h r ea ds wit h ING - STANDARD P ROCE DURE ).
clea n en gin e oil a n d in st a ll t h e t en M11 bolt s. (17) Ra ise t h e veh icle.
(5) Coa t t h e fou r M8 cylin der h ea d bolt s wit h (18) In st a ll t h e exh a u st pipe on t o t h e left exh a u st
Mo p a r! Lo c k a n d S e a l Ad h e s iv e t h en in st a ll t h e m a n ifold.
bolt s. (19) Lower t h e veh icle.
(20) Con n ect t h e n ega t ive ca ble t o t h e ba t t er y.
NOTE: The cylinder head bolts are tightened using (21) St a r t t h e en gin e a n d ch eck for lea ks.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tigh t en t h e bolt s in sequ en ce (F ig. 14) u sin g

t h e followin g st eps a n d t or qu e va lu es:
• St ep 1: Tigh t en bolt s 1–10, 20 N·m (15 ft . lbs.).
Tigh t en bolt s 11–14, 25 N·m (18 ft . lbs.).
• St ep 3: Tigh t en bolt s 1–10, 90 degr ees. Tigh t en
bolt s 11–14, 26 N·m (19 ft . lbs.).
CAM SH AFT (S) - LEFT (2) Set en gin e t o TDC cylin der #1, ca m sh a ft
spr ocket V8 m a r ks a t t h e 12 o’clock posit ion .
(3) Ma r k on e lin k on t h e secon da r y t im in g ch a in
DESCRIPTION
on bot h sides of t h e V8 m a r k on t h e ca m sh a ft
Th e ca m sh a ft s con sist of powder ed m et a l st eel
spr ocket t o a id in in st a lla t ion .
lobes wh ich a r e sin t er-bon ded t o a st eel t u be. A st eel
post or n ose piece is fr ict ion -welded t o t h e st eel ca m - CAUTION: Do not hold or pry on the camshaft tar-
sh a ft t u be. F ive bea r in g jou r n a ls a r e m a ch in ed in t o get wheel (Located on the right side camshaft
t h e ca m sh a ft , fou r on t h e st eel t u be a n d on e on t h e sprocket) for any reason, Severe damage will occur
st eel n ose piece. Ca m sh a ft en d pla y is con t r olled by to the target wheel resulting in a vehicle no start
t wo t h r u st wa lls t h a t bor der t h e n ose piece jou r n a l. condition.
E n gin e oil en t er s t h e h ollow ca m sh a ft s a t t h e t h ir d
jou r n a l a n d lu br ica t es ever y in t a ke lobe r ocker (4) Loosen bu t D O N OT r em ove t h e ca m sh a ft
t h r ou gh a dr illed pa ssa ge in t h e in t a ke lobe. spr ocket r et a in in g bolt . Lea ve t h e bolt sn u g a ga in st
t h e spr ocket .
REMOVAL
NOTE: The timing chain tensioners must be
CAUTION: When the timing chain is removed and secured prior to removing the camshaft sprockets.
the cylinder heads are still installed, DO NOT force- Failure to secure tensioners will allow the tension-
fully rotate the camshafts or crankshaft indepen- ers to extend, requiring timing chain cover removal
dently of each other. Severe valve and/or piston in order to reset tensioners.
damage can occur.
CAUTION: Do not force wedge past the narrowest

CAUTION: When removing the cam sprocket, timing point between the chain strands. Damage to the
chains or camshaft, Failure to use Special Tool tensioners may occur.
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to (5) P osit ion Specia l Tool 8350 t im in g ch a in wedge
reset the tensioner ratchet. bet ween t h e t im in g ch a in st r a n ds, t a p t h e t ool t o
secu r ely wedge t h e t im in g ch a in a ga in st t h e t en -
(1) Rem ove cylin der h ea d cover (Refer t o 9 - sion er a r m a n d gu ide (F ig. 15).
COVE R(S) - RE MOVAL) .
CAM SH AFT (S) - LEFT (Cont inue d)
Fig. 15 Securing Timing Chain Tensioners Using Timing Chain Wedge

1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE
2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE
(6) H old t h e ca m sh a ft wit h a dju st a ble plier s wh ile

r em ovin g t h e ca m sh a ft spr ocket bolt a n d spr ocket
(F ig. 16).
Fig. 16 Camshaft Sprocket and Chain

1 - CAMSHAFT SPROCKET AND CHAIN
2 - ADJUSTABLE PLIERS
3 - CAMSHAFT
(7) Usin g t h e plier s, gen t ly a llow t h e ca m sh a ft t o
r ot a t e 15° clockwise u n t il t h e ca m sh a ft is in t h e n eu -
t r a l posit ion (n o va lve loa d).
(8) St a r t in g a t t h e ou t side wor kin g in wa r d, loosen
t h e ca m sh a ft bea r in g ca p r et a in in g bolt s 1/2 t u r n a t
a t im e. Repea t u n t il a ll loa d is off t h e bea r in g ca ps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-

SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker

arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e

ca m sh a ft .
INSTALLATION
(1) Lu br ica t e ca m sh a ft jou r n a ls wit h clea n en gin e
oil.
NOTE: Position the left side camshaft so that the Fig. 17 Camshaft Bearing Caps Tightening
camshaft sprocket dowel is near the 1 o’clock posi- Sequence
tion, This will place the camshaft at the neutral (5) Tor qu e t h e ca m sh a ft bea r in g ca p r et a in in g
position easing the installation of the camshaft bolt s t o 11 N·m (100 in . lbs.).
bearing caps.
(2) P osit ion t h e ca m sh a ft in t o t h e cylin der h ea d.

(3) In st a ll t h e ca m sh a ft bea r in g ca ps, h a n d t igh t en
t h e r et a in in g bolt s.
(4) Wor kin g in 1 ⁄2 t u r n in cr em en t s, t igh t en t h e
bea r in g ca p r et a in in g bolt s st a r t in g wit h t h e m iddle
ca p wor kin g ou t wa r d (F ig. 17).
(6) P osit ion t h e ca m sh a ft dr ive gea r in t o t h e t im -
in g ch a in a lign in g t h e V8 m a r k bet ween t h e t wo
m a r ked ch a in lin ks (Two lin ks m a r ked du r in g
r em ova l) (F ig. 18).
Fig. 18 Timing Chain to Sprocket Alignment

(7) Usin g t h e a dju st a ble plier s, r ot a t e t h e ca m -
sh a ft u n t il t h e ca m sh a ft spr ocket dowel is a lign ed
wit h t h e slot in t h e ca m sh a ft spr ocket . In st a ll t h e
spr ocket on t o t h e ca m sh a ft (F ig. 19).
CAUTION: Remove excess oil from camshaft

sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Rem ove excess oil fr om bolt , t h en in st a ll t h e

ca m sh a ft spr ocket r et a in in g bolt a n d h a n d t igh t en .
(9) Rem ove Specia l Tool 8350 t im in g ch a in wedge
(F ig. 20).
Fig. 19 Camshaft Sprocket Installation

2 - CAMSHAFT DOWEL
Fig. 20 SPECIAL TOOL 8350

(10) Usin g Specia l Tool 6958 spa n n er wr en ch wit h (3) Discon n ect in ject or con n ect or s a n d u n -clip t h e
a da pt er pin s 8346 (F ig. 21), t or qu e t h e ca m sh a ft in ject or h a r n ess.
spr ocket r et a in in g bolt t o 122 N·m (90 ft . lbs.). (4) Rou t e in ject or h a r n ess in fr on t of cylin der h ea d
(11) In st a ll t h e cylin der h ea d cover. cover.
(5) Discon n ect t h e left side br ea t h er t u be a n d
r em ove t h e br ea t h er t u be.
(6) Rem ove t h e cylin der h ea d cover m ou n t in g
bolt s.
(7) Rem ove cylin der h ea d cover a n d ga sket .
NOTE: The gasket may be used again, provided no

cuts, tears, or deformation has occurred.
CLEANING
Clea n cylin der h ea d cover ga sket su r fa ce.
Clea n h ea d r a il, if n ecessa r y.
INSTALLATION—LEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-

ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Clea n cylin der h ea d cover a n d bot h sea lin g su r-

fa ces. In spect a n d r epla ce ga sket a s n ecessa r y.
Fig. 21 Tightening Left Side Cam Sprocket (2) In st a ll cylin der h ea d cover a n d h a n d st a r t a ll
Retaining Bolt fa st en er s. Ver ify t h a t a ll st u ds a r e in t h e cor r ect loca -
t ion sh own in (F ig. 22).
1 - TORQUE WRENCH
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
CY LI N DER H EAD COV ER(S) -

LEFT
DESCRIPTION
Th e cylin der h ea d cover s a r e m a de of die ca st m a g-
n esiu m , a n d a r e n ot in t er ch a n gea ble fr om side-t o-
side. It is im per a t ive t h a t n ot h in g r est on t h e
cylin der h ea d cover s. P r olon ged con t a ct wit h ot h er
it em s m a y wea r a h ole in t h e cylin der h ea d cover. Fig. 22 Cylinder Head Cover—Left
ITEM DESCRIPTION TORQUE
REMOVAL—LEFT SIDE 1 Cover Fasteners 12 N·m (105 in. lbs.)

(2) Rem ove t h e r eson a t or a ssem ble a n d a ir in let (3) Tigh t en cylin der h ea d cover bolt s a n d dou ble
h ose. en ded st u ds t o 12 N·m (105 in . lbs.).
CY LI N DER H EAD COV ER(S) - LEFT (Cont inue d)
(4) In st a ll left side br ea t h er a n d con n ect br ea t h er
t u be.
(5) Con n ect in ject or elect r ica l con n ect or s a n d in jec-
t or h a r n ess r et a in in g clips.
(6) In st a ll t h e r eson a t or a n d a ir in let h ose.
I N TAK E/EX H AU ST VALV ES &

SEAT S
DESCRIPTION
Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. E a ch
va lve is a ct u a t ed by a r oller r ocker a r m wh ich pivot s
on a st a t ion a r y la sh a dju st er. All va lves u se t h r ee
bea d lock keeper s t o r et a in t h e spr in gs a n d pr om ot e
va lve r ot a t ion .
STANDARD PROCEDURE—REFACING
NOTE: Valve seats that are worn or burned can be Fig. 23 Valve Assembly Configuration
reworked, provided that correct angle and seat 1 - VALVE LOCKS (3–BEAD)
width are maintained. Otherwise the cylinder head 2 - RETAINER
must be replaced. 3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
NOTE: When refacing valves and valve seats, it is 6 - VALVE SPRING
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained. REMOVAL
(1) Usin g a su it a ble dia l in dica t or m ea su r e t h e NOTE: The cylinder heads must be removed in
cen t er of t h e va lve sea t Tot a l r u n ou t m u st n ot order to preform this procedure.
exceed 0.051 m m (0.002 in ).
(2) Apply a sm a ll a m ou n t of P r u ssia n blu e t o t h e (1) Usin g Specia l Tool 8516 Va lve Spr in g Com pr es-
va lve sea t , in ser t t h e va lve in t o t h e cylin der h ea d, sor, r em ove t h e r ocker a r m s a n d t h e h ydr a u lic la sh
wh ile a pplyin g ligh t pr essu r e on t h e va lve r ot a t e t h e a dju st er s (F ig. 24).
va lve. Rem ove t h e va lve a n d exa m in e t h e va lve fa ce. (2) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e
If t h e blu e is t r a n sfer r ed below t h e t op edge of t h e ca m sh a ft .
va lve fa ce, lower t h e va lve sea t u sin g a 15 degr ee
st on e. If t h e blu e is t r a n sfer r ed t o t h e bot t om edge of NOTE: All eight valve springs and valves are
t h e va lve fa ce, r a ise t h e va lve sea t u sin g a 65 degr ee removed in the same manner; this procedure only
st on e. covers one valve and valve spring.
(3) Wh en t h e sea t is pr oper ly posit ion ed t h e widt h
of t h e in t a ke sea t m u st be 1.75 – 2.36 m m (0.0689 – (3) Usin g Specia l Tool C-3422–B or C-3422–C
0.0928 in .) a n d t h e exh a u st sea t m u st be 1.71 – 2.32 Va lve Spr in g Com pr essor a n d Specia l t ool 8519
m m (0.0673 – 0.0911 in .). Ada pt er, com pr ess t h e va lve spr in g.
(4) Ch eck t h e va lve spr in g in st a lled h eigh t a ft er
NOTE: It may be necessary to tap the top of the
r efa cin g t h e va lve a n d sea t . Th e in st a lled h eigh t for
valve spring to loosen the spring retainers locks
bot h in t a ke a n d exh a u st va lve spr in gs m u st n ot
enough to be removed.
exceed 41.44 m m (1.6315 in .) .
(5) Th e va lve sea t a n d va lve fa ce m u st m a in t a in a (4) Rem ove t h e t wo spr in g r et a in er lock h a lves.
fa ce a n gle of 44.5 – 45 degr ees a n gle (F ig. 23).
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
a dju st m en t s. Refer t o Specifica t ion s Sect ion t o obt a in
specified h eigh t a n d a llowa ble t en sion s. Repla ce a n y
spr in gs t h a t do n ot m eet specifica t ion s. (F ig. 25)
Fig. 25 Testing Valve Springs

1 - SPECIAL TOOL C-647
Fig. 24 Rocker Arm Removal

1 - CAMSHAFT
INSTALLATION
2 - SPECIAL TOOL 8516 (1) coa t t h e va lve st em wit h clea n en gin e oil a n d
in ser t it in t o t h e cylin der h ea d.
(2) In st a ll t h e va lve st em sea l. m a ke su r e t h e sea l
(5) Rem ove t h e va lve spr in g com pr essor. is fu lly sea t ed a n d t h a t t h e ga r t er spr in g a t t h e t op
(6) Rem ove t h e spr in g r et a in er, a n d t h e spr in g. of t h e sea l is in t a ct .
(3) In st a ll t h e spr in g a n d t h e spr in g r et a in er (F ig.
NOTE: Check for sharp edges on the keeper
26).
grooves. Remove any burrs from the valve stem
(4) Usin g t h e va lve spr in g com pr essor, com pr ess
before removing the valve from the cylinder head.
t h e spr in g a n d in st a ll t h e t wo va lve spr in g r et a in er
(7) Rem ove t h e va lve fr om t h e cylin der h ea d. h a lves.
(5) Relea se t h e va lve spr in g com pr essor a n d m a ke
NOTE: The valve stem seals are common between su r e t h e t wo spr in g r et a in er h a lves a n d t h e spr in g
intake and exhaust. r et a in er a r e fu lly sea t ed.
(6) lu br ica t e t h e ca m sh a ft jou r n a l wit h clea n
(8) Rem ove t h e va lve st em sea l. Ma r k t h e va lve for en gin e oil t h en P osit ion t h e ca m sh a ft (wit h t h e
pr oper in st a lla t ion . spr ocket dowel on t h e left ca m sh a ft a t 11 o’clock a n d
t h e r igh t ca m sh a ft a t 12 o’clock), t h en posit ion t h e
TESTING VALVE SPRINGS ca m sh a ft bea r in g ca ps.
(7) In st a ll t h e ca m sh a ft bea r in g ca p r et a in in g
NOTE: Whenever the valves are removed from the bolt s. Tigh t en t h e bolt s 9–13 N·m (100 in . lbs.) in 1 ⁄2
cylinder head it is recommended that the valve t u r n in cr em en t s in t h e sequ en ce sh own (F ig. 27).
springs be inspected and tested for reuse. (8) P osit ion t h e h ydr a u lic la sh a dju st er s a n d
r ocker a r m s (F ig. 24).
In spect t h e va lve spr in gs for ph ysica l sign s of wea r
or da m a ge. Tu r n t a ble of t ool C-647 u n t il su r fa ce is
in lin e wit h t h e 40.69 m m (1.602 in .) m a r k on t h e ROCK ER ARM / ADJ U ST ER
t h r ea ded st u d a n d t h e zer o m a r k on t h e fr on t . P la ce
spr in g over t h e st u d on t h e t a ble a n d lift com pr ess- ASSEM BLY
in g lever t o set t on e device. P u ll on t or qu e wr en ch
u n t il P in g is h ea r d. Ta ke r ea din g on t or qu e wr en ch DESCRIPTION
a t t h is in st a n t . Mu lt iply t h is r ea din g by t wo. Th is Th e r ocker a r m s a r e st eel st a m pin gs wit h a n in t e-
will give t h e spr in g loa d a t t est len gt h . F r a ct ion a l gr a l r oller bea r in g. Th e r ocker a r m s in cor por a t e a 2.8
m ea su r em en t s a r e in dica t ed on t h e t a ble for fin er
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Rem ove t h e cylin der h ea d cover. Refer t o Cyl-

in der H ea d Cover in t h is sect ion .
(2) F or r ocker a r m r em ova l on cylin der s 3 a n d 5
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
exh a u st st r oke.
com pr ession st r oke.
(6) Usin g specia l t ool 8516 pr ess down wa r d on t h e
va lve spr in g, r em ove r ocker a r m (F ig. 28).
Fig. 26 Valve Assembly Configuration
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 28 Rocker Arm—Removal

1 - CAMSHAFT
INSTALLATION
CAUTION: Make sure the rocker arms are installed
Fig. 27 Camshaft Bearing Caps Tightening with the concave pocket over the lash adjusters.
Sequence Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
m m (0.11 in ch ) oil h ole in t h e la sh a dju st er socket for
r oller a n d ca m sh a ft lu br ica t ion .
NOTE: Coat the rocker arms with clean engine oil DIAGNOSIS AND TESTING—CYLINDER HEAD
prior to installation.
GASKET
(1) F or r ocker a r m in st a lla t ion on cylin der s 3 a n d A cylin der h ea d ga sket lea k ca n be loca t ed bet ween
5 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC a dja cen t cylin der s or bet ween a cylin der a n d t h e
exh a u st st r oke. a dja cen t wa t er ja cket .
(2) F or r ocker a r m in st a lla t ion on cylin der s 2 a n d P ossible in dica t ion s of t h e cylin der h ea d ga sket
8 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC lea kin g bet ween a dja cen t cylin der s a r e:
com pr ession st r oke. • Loss of en gin e power
(3) F or r ocker a r m in st a lla t ion on cylin der s 4 a n d • E n gin e m isfir in g
6 Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC • P oor fu el econ om y
com pr ession st r oke. P ossible in dica t ion s of t h e cylin der h ea d ga sket
(4) F or r ocker a r m in st a lla t ion on cylin der s 1 a n d lea kin g bet ween a cylin der a n d a n a dja cen t wa t er
7 Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC ja cket a r e:
com pr ession st r oke. • E n gin e over h ea t in g
(5) Usin g specia l t ool 8516 pr ess down wa r d on t h e • Loss of coola n t
va lve spr in g, in st a ll r ocker a r m (F ig. 28). • E xcessive st ea m (wh it e sm oke) em it t in g fr om
(6) In st a ll t h e cylin der h ea d cover. exh a u st
• Coola n t foa m in g
VALV E SPRI N GS CYLINDER-TO-CYLINDER LEAKAGE TEST

To det er m in e if a n en gin e cylin der h ea d ga sket is
DESCRIPTION lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce-
Th e va lve spr in gs a r e m a de fr om h igh st r en gt h du r es in Cylin der Com pr ession P r essu r e Test (Refer
ch r om e silicon st eel. Th e spr in gs a r e com m on for t o 9 - E NGINE - DIAGNOSIS AND TE STING). An
in t a ke a n d exh a u st a pplica t ion s. Th e va lve spr in g en gin e cylin der h ea d ga sket lea kin g bet ween a dja -
sea t is in t egr a l wit h t h e va lve st em sea l, wh ich is a cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70%
posit ive t ype sea l t o con t r ol lu br ica t ion . r edu ct ion in com pr ession pr essu r e.
CYLINDER-TO-WATER JACKET LEAKAGE TEST

VALV E ST EM SEALS
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
DESCRIPTION
SURE CAP REMOVED.
Th e va lve st em sea ls a r e m a de of r u bber a n d in cor-
por a t e a n in t egr a l st eel va lve spr in g sea t . Th e in t e-
gr a l ga r t er spr in g m a in t a in s con sist en t lu br ica t ion VISUAL TEST METHOD
con t r ol t o t h e va lve st em s. Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e
ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il
t h er m ost a t open s.
CY LI N DER H EAD - RI GH T If a la r ge com bu st ion /com pr ession pr essu r e lea k
exist s, bu bbles will be visible in t h e coola n t .
DESCRIPTION—CYLINDER HEAD
Th e cylin der h ea ds a r e m a de of a n a lu m in u m a lloy. COOLING SYSTEM TESTER METHOD
Th e cylin der h ea d fea t u r es t wo va lves per cylin der
wit h pr essed in powder ed m et a l va lve gu ides. Th e WARNING: WITH COOLING SYSTEM TESTER IN
cylin der h ea ds a lso pr ovide en closu r es for t h e t im in g PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
ch a in dr a in , n ecessit a t in g u n iqu e left a n d r igh t cylin - SIVE PRESSURE BUILT UP, BY CONTINUOUS
der h ea ds. ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
DESCRIPTION—VALVE GUIDES SURE TO EXCEED 138 kPa (20 psi).
Th e va lve gu ides a r e m a de of power ed m et a l a n d
a r e pr essed in t o t h e cylin der h ea d. Th e gu ides a r e In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o
n ot r epla cea ble or ser vicea ble, a n d va lve gu ide r ea m - pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e
in g is n ot r ecom m en ded. If t h e gu ides a r e wor n t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y
beyon d a ccept a ble lim it s, r epla ce t h e cylin der h ea ds. power st r oke of a cylin der a com bu st ion pr essu r e
lea k is eviden t .
CY LI N DER H EAD - RI GH T (Cont inue d)
CHEMICAL TEST METHOD (9) Rem ove a ccessor y dr ive belt (Refer t o 7 -
Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or RE MOVAL).
equ iva len t . P er for m t est followin g t h e pr ocedu r es (10) Rot a t e t h e cr a n ksh a ft u n t il t h e da m per t im -
su pplied wit h t h e t ool kit . in g m a r k is a lign ed wit h TDC in dica t or m a r k (F ig.
9).
DIAGNOSIS AND TESTING—HYDRAULIC LASH (11) Ver ify t h e V8 m a r k on t h e ca m sh a ft spr ocket
ADJUSTER NOISE DIAGNOSIS is a t t h e 12 o’clock posit ion (F ig. 11). Rot a t e t h e
cr a n ksh a ft on e t u r n if n ecessa r y.
A t a ppet -like n oise m a y be pr odu ced fr om sever a l
(12) Rem ove t h e cr a n ksh a ft da m per (Refer t o 9 -
it em s. Ch eck t h e followin g it em s.
(1) E n gin e oil level t oo h igh or t oo low. Th is m a y
RE MOVAL).
ca u se a er a t ed oil t o en t er t h e a dju st er s a n d ca u se
(13) Rem ove t h e t im in g ch a in cover (Refer t o 9 -
t h em t o be spon gy.
(2) In su fficien t r u n n in g t im e a ft er r ebu ildin g cylin -
der h ea d. Low speed r u n n in g u p t o 1 h ou r m a y be
(14) Lock t h e secon da r y t im in g ch a in s t o t h e idler
r equ ir ed.
spr ocket u sin g Specia l Tool 8515 (F ig. 10).
(3) Tu r n en gin e off a n d let set for a few m in u t es
befor e r est a r t in g. Repea t t h is sever a l t im es a ft er NOTE: Mark the secondary timing chain prior to
en gin e h a s r ea ch ed n or m a l oper a t in g t em per a t u r e. removal to aid in installation.
(4) Low oil pr essu r e.
(5) Th e oil r est r ict or in cylin der h ea d ga sket or t h e (15) Ma r k t h e secon da r y t im in g ch a in , on e lin k on
oil pa ssa ge t o t h e cylin der h ea d is plu gged wit h ea ch side of t h e V8 m a r k on t h e ca m sh a ft dr ive gea r
debr is. (F ig. 11).
(6) Air in gest ed in t o oil du e t o br oken or cr a cked (16) Rem ove t h e r igh t side secon da r y ch a in t en -
oil pu m p pick u p. sion er (Refer t o 9 - E NGINE /VALVE TIMING/TIM-
(7) Wor n va lve gu ides. ING BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
(8) Rocker a r m ea r s con t a ct in g va lve spr in g (17) Rem ove t h e cylin der h ea d a ccess plu g (F ig.
r et a in er. 29).
(9) Rocker a r m loose, a dju st er st u ck or a t m a xi-
m u m ext en sion a n d st ill lea ves la sh in t h e syst em .
(10) F a u lt y la sh a dju st er.
• Ch eck la sh a dju st er s for spon gin ess wh ile
in st a lled in cylin der h ea d a n d ca m on ca m sh a ft a t
ba se cir cle. Depr ess pa r t of r ocker a r m over a dju st er.
Nor m a l a dju st er s sh ou ld feel ver y fir m . Spon gy
a dju st er s ca n be bot t om ed ou t ea sily.
• Rem ove su spect ed la sh a dju st er s, a n d r epla ce.
• Befor e in st a lla t ion , m a ke su r e a dju st er s a r e a t
lea st pa r t ia lly fu ll of oil. Th is ca n be ver ified by lit t le
or n o plu n ger t r a vel wh en la sh a dju st er is depr essed.
REMOVAL
(1) Discon n ect ba t t er y n egit ive ca ble.
(2) Ra ise t h e veh icle on a h oist .
(3) Discon n ect t h e exh a u st pipe a t t h e r igh t side Fig. 29 Cylinder Head Access Plugs
exh a u st m a n ifold. 1 - RIGHT CYLINDER HEAD ACCESS PLUG
(4) Dr a in t h e en gin e coola n t (Refer t o 7 - COOL- 2 - LEFT CYLINDER HEAD ACCESS PLUG
ING - STANDARD P ROCE DURE ).
(6) Rem ove t h e in t a ke m a n ifold (Refer t o 9 - (18) Rem ove t h e r igh t side secon da r y ch a in gu ide
E NGINE /MANIF OLDS/INTAKE MANIF OLD - (Refer t o 9 - E NGINE /VALVE TIMING/TIMING
RE MOVAL). BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
(7) Rem ove t h e cylin der h ea d cover (Refer t o 9 - (19) Rem ove t h e r et a in in g bolt a n d t h e ca m sh a ft
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD dr ive gea r.
(8) Rem ove oil fill h ou sin g fr om cylin der h ea d.
CAUTION: Do not allow the engine to rotate. severe CAUTION: When cleaning cylinder head and cylin-
damage to the valve train can occur. der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to (1) Clea n t h e cylin der h ea d a n d cylin der block
remove the cylinder head without removing these m a t in g su r fa ces (Refer t o 9 - E NGINE - STANDARD
four bolts. P ROCE DURE ).
(2) P osit ion t h e n ew cylin der h ea d ga sket on t h e
loca t in g dowels.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel CAUTION: When installing cylinder head, use care
can result in a vehicle no start condition. not damage the tensioner arm or the guide arm.
(3) P osit ion t h e cylin der h ea d on t o t h e cylin der

NOTE: The cylinder head is attached to the cylinder
block. Ma ke su r e t h e cylin der h ea d sea t s fu lly over
block with fourteen bolts.
t h e loca t in g dowels.
(20) Rem ove t h e cylin der h ea d r et a in in g bolt s.
NOTE: The four smaller cylinder head mounting
(21) Rem ove t h e cylin der h ea d a n d ga sket . Disca r d
bolts require sealant to be added to them before
t h e ga sket .
installing. Failure to do so may cause leaks.
CAUTION: Do not lay the cylinder head on its gas-
(4) Lu br ica t e t h e cylin der h ea d bolt t h r ea ds wit h
ket sealing surface, do to the design of the cylinder
clea n en gin e oil a n d in st a ll t h e t en M10 bolt s.
head gasket any distortion to the cylinder head
(5) Coa t t h e fou r M8 cylin der h ea d bolt s wit h
sealing surface may prevent the gasket from prop-
Mo p a r Lo c k a n d S e a l Ad h e s iv e t h en in st a ll t h e
erly sealing resulting in leaks.
bolt s.

CLEANING an angle torque procedure, however, the bolts are
To en su r e en gin e ga sket sea lin g, pr oper su r fa ce not a torque-to-yield design.
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s. (Refer t o 9 - (6) Tigh t en t h e bolt s in sequ en ce (F ig. 30) u sin g
E NGINE - STANDARD P ROCE DURE ) t h e followin g st eps a n d t or qu e va lu es:
INSPECTION • St ep 2: Tigh t en bolt s 1–10, 47 N·m (35 ft . lbs.).
(1) In spect t h e cylin der h ea d for ou t -of-fla t n ess, Tigh t en bolt s 11–14, 25 N·m (18 ft . lbs.).
u sin g a st r a igh t edge a n d a feeler ga u ge. If t oler a n ces • St ep 3: Tigh t en bolt s 1–10, 90 degr ees. Tigh t en
exceed 0.0508 m m (0.002 in .) r epla ce t h e cylin der bolt s 11–14, 26 N·m (19 ft . lbs.).
h ea d.
(2) In spect t h e va lve sea t s for da m a ge. Ser vice t h e
va lve sea t s a s n ecessa r y.
(3) In spect t h e va lve gu ides for wea r, cr a cks or
loosen ess. If eit h er con dit ion exist , r epla ce t h e cylin -
der h ea d.
INSTALLATION
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Neckin g ca n be ch ecked by h oldin g a st r a igh t edge

Fig. 30 Cylinder Head Tightening Sequence
a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds do n ot con t a ct
t h e sca le, t h e bolt sh ou ld be r epla ced (F ig. 13). (7) In st a ll t h e secon da r y ch a in a n d secon da r y
ch a in gu ide (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT/CH AIN AND SP ROCKE TS - CAUTION: When removing the cam sprocket, timing
INSTALLATION). chains or camshaft, Failure to use special tool 8350
(8) In st a ll t h e cylin der h ea d a ccess plu g. will result in hydraulic tensioner ratchet over exten-
(9) Re-set a n d in st a ll t h e r igh t side secon da r y sion, Requiring timing chain cover removal to re-set
ch a in t en sion er (Refer t o 9 - E NGINE /VALVE TIM- the tensioner ratchet.
ING/TIMING BE LT/CH AIN AND SP ROCKE TS -
INSTALLATION). (1) Rem ove t h e cylin der h ea d cover s (Refer t o 9 -
(10) Rem ove Specia l Tool 8515. E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
(11) In st a ll t h e t im in g ch a in cover (Refer t o 9 - COVE R(S) - RE MOVAL).
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN (2) Set en gin e t o TDC cylin der #1, ca m sh a ft
COVE R(S) - INSTALLATION). spr ocket V8 m a r ks a t t h e 12 o’clock posit ion .
(12) In st a ll t h e cr a n ksh a ft da m per (Refer t o 9 - (3) Ma r k on e lin k on t h e secon da r y t im in g ch a in
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R - on bot h sides of t h e V8 m a r k on t h e ca m sh a ft
INSTALLATION). spr ocket t o a id in in st a lla t ion .
(13) In st a ll a ccessor y dr ive belt (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - CAUTION: Do not hold or pry on the camshaft tar-
INSTALLATION). get wheel for any reason, Severe damage will occur
(14) In st a ll t h e cylin der h ea d cover (Refer t o 9 - to the target wheel. A damaged target wheel could
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD cause a vehicle no start condition.
(4) Loosen bu t D O N OT r em ove t h e ca m sh a ft
(15) In st a ll t h e in t a ke m a n ifold (Refer t o 9 -
spr ocket r et a in in g bolt . Lea ve bolt sn u g a ga in st
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
spr ocket .
INSTALLATION).
(16) In st a ll oil fill h ou sin g on t o cylin der h ea d. NOTE: The timing chain tensioners must be
(17) Refill t h e coolin g syst em (Refer t o 7 - COOL- secured prior to removing the camshaft sprockets.
ING - STANDARD P ROCE DURE ). Failure to secure tensioners will allow the tension-
(18) Ra ise t h e veh icle. ers to extend, requiring timing chain cover removal
(19) In st a ll t h e exh a u st pipe on t o t h e r igh t in order to reset tensioners.
exh a u st m a n ifold.
(21) Recon n ect ba t t er y n egit ive ca ble. CAUTION: Do not force wedge past the narrowest
(22) St a r t t h e en gin e a n d ch eck for lea ks. point between the chain strands. Damage to the
tensioners may occur.
CAM SH AFT (S) - RI GH T (5) P osit ion Specia l Tool 8350 t im in g ch a in wedge
bet ween t h e t im in g ch a in st r a n ds. Ta p t h e t ool t o
DESCRIPTION secu r ely wedge t h e t im in g ch a in a ga in st t h e t en -
Th e ca m sh a ft s con sist of powder ed m et a l st eel sion er a r m a n d gu ide (F ig. 31).
lobes wh ich a r e sin t er-bon ded t o a st eel t u be. A st eel (6) Rem ove t h e ca m sh a ft posit ion sen sor (F ig. 32).
post or n ose piece is fr ict ion -welded t o t h e st eel ca m - (7) H old t h e ca m sh a ft wit h a dju st a ble plier s wh ile
sh a ft t u be. F ive bea r in g jou r n a ls a r e m a ch in ed in t o r em ovin g t h e ca m sh a ft spr ocket bolt a n d spr ocket
t h e ca m sh a ft , fou r on t h e st eel t u be a n d on e on t h e (F ig. 33).
st eel n ose piece. Ca m sh a ft en d pla y is con t r olled by (8) Usin g t h e plier s, gen t ly a llow t h e ca m sh a ft t o
t wo t h r u st wa lls t h a t bor der t h e n ose piece jou r n a l. r ot a t e 45° cou n t er-clockwise u n t il t h e ca m sh a ft is in
E n gin e oil en t er s t h e h ollow ca m sh a ft s a t t h e t h ir d t h e n eu t r a l posit ion (n o va lve loa d).
jou r n a l a n d lu br ica t es ever y in t a ke lobe r ocker (9) St a r t in g a t t h e ou t side wor kin g in wa r d, loosen
t h r ou gh a dr illed pa ssa ge in t h e in t a ke lobe. t h e ca m sh a ft bea r in g ca p r et a in in g bolt s 1/2 t u r n a t
a t im e. Repea t u n t il a ll loa d is off t h e bea r in g ca ps.
REMOVAL
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
CAUTION: When the timing chain is removed and SHAFT BEARING CAPS. SEVERE DAMAGE WILL
the cylinder heads are still installed, DO NOT force- OCCUR TO THE BEARING CAPS.
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston NOTE: When the camshaft is removed the rocker
damage can occur.
arms may slide downward, mark the rocker arms
before removing camshaft.
CAM SH AFT (S) - RI GH T (Cont inue d)

(10) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e (7) Usin g t h e a dju st a ble plier s, r ot a t e t h e ca m -

ca m sh a ft . sh a ft u n t il t h e ca m sh a ft spr ocket dowel is a lign ed
wit h t h e slot in t h e ca m sh a ft spr ocket . In st a ll t h e
INSTALLATION spr ocket on t o t h e ca m sh a ft (F ig. 36).
(1) Lu br ica t e ca m sh a ft jou r n a ls wit h clea n en gin e
oil. CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
NOTE: Position the right side camshaft so that the torque resulting in bolt failure.
camshaft sprocket dowel is near the 10 o’clock
position, This will place the camshaft at the neutral (8) Rem ove excess oil fr om ca m sh a ft spr ocket bolt ,
position easing the installation of the camshaft t h en in st a ll t h e ca m sh a ft spr ocket r et a in in g bolt a n d
bearing caps. h a n d t igh t en .
(9) Rem ove t im in g ch a in wedge specia l t ool 8350
(2) P osit ion t h e ca m sh a ft in t o t h e cylin der h ea d. (F ig. 31).
(3) In st a ll t h e ca m sh a ft bea r in g ca ps, h a n d t igh t en (10) Usin g Specia l Tool 6958 spa n n er wr en ch wit h
t h e r et a in in g bolt s. a da pt er pin s 8346 (F ig. 37), t or qu e t h e ca m sh a ft
(4) Wor kin g in 1/2 t u r n in cr em en t s, t igh t en t h e spr ocket r et a in in g bolt t o 122 N·m (90 ft . lbs.).
bea r in g ca p r et a in in g bolt s st a r t in g wit h t h e m iddle (11) In st a ll t h e ca m sh a ft posit ion sen sor (F ig. 32).
ca p wor kin g ou t wa r d (F ig. 34). (12) In st a ll t h e cylin der h ea d cover (Refer t o 9 -
(5) Tor qu e t h e ca m sh a ft bea r in g ca p r et a in in g E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
bolt s t o 11 N·m (100 in . lbs.). COVE R(S) - INSTALLATION).
(6) P osit ion t h e ca m sh a ft dr ive gea r in t o t h e t im -
in g ch a in a lign in g t h e V8 m a r k bet ween t h e t wo
m a r ked ch a in lin ks (Two lin ks m a r ked du r in g
r em ova l) (F ig. 35).
Fig. 32 Camshaft Position Sensor

Fig. 34 Camshaft Bearing Caps Tightening
1 - CRANKSHAFT POSITION SENSOR
Sequence
2 - CYLINDER HEAD COVER
Fig. 33 Camshaft Sprocket and Chain

2 - SPROCKET BOLT
3 - CAMSHAFT SPROCKET AND CHAIN
4 - CAMSHAFT
Fig. 35 Timing Chain to Sprocket Alignment

Fig. 37 Tightening Right Side Cam Sprocket

Retaining Bolt
1 - TORQUE WRENCH
Fig. 36 Camshaft Sprocket Installation 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
1 - ADJUSTABLE PLIERS 3 - LEFT CAMSHAFT SPROCKET
2 - CAMSHAFT DOWEL 4 - RIGHT CAMSHAFT SPROCKET
CY LI N DER H EAD COV ER(S) - (2) In st a ll cylin der h ea d cover a n d h a n d st a r t a ll

fa st en er s. Ver ify t h a t a ll dou ble en ded st u ds a r e in
RI GH T t h e cor r ect loca t ion sh own in (F ig. 38).
DESCRIPTION
Th e cylin der h ea d cover s a r e m a de of die ca st m a g-
n esiu m , a n d a r e n ot in t er ch a n gea ble fr om side-t o-
side. It is im per a t ive t h a t n ot h in g r est on t h e
cylin der h ea d cover s. P r olon ged con t a ct wit h ot h er
it em s m a y wea r a h ole in t h e cylin der h ea d cover.
REMOVAL—RIGHT SIDE
(1) Discon n ect ba t t er y n ega t ive ca ble.
(2) Rem ove a ir clea n er a ssem bly, r eson a t or a ssem -
bly a n d a ir in let h ose.
STANDARD P ROCE DURE ). Fig. 38 Cylinder Head Cover—Right
(4) Rem ove a ccessor y dr ive belt (Refer t o 7 - ITEM DESCRIPTION TORQUE
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - 1 Cover Fasteners 12 N·m (105 in. lbs.)
RE MOVAL).
(5) Rem ove a ir con dit ion in g com pr essor r et a in in g
bolt s a n d m ove com pr essor t o t h e left . (3) Tigh t en cylin der h ea d cover bolt s a n d dou ble
(6) Rem ove h ea t er h oses. en ded st u ds t o 12 N·m (105 in . lbs).
(7) Discon n ect in ject or a n d ign it ion coil con n ect or s. (4) In st a ll r igh t r ea r br ea t h er t u be a n d filt er
(8) Discon n ect a n d r em ove posit ive cr a n kca se ven - a ssem bly.
t ila t ion (P CV) h ose. (5) Con n ect in ject or, ign it ion coil elect r ica l con n ec-
(9) Rem ove oil fill t u be. t or s a n d h a r n ess r et a in in g clips.
(10) Un -clip in ject or a n d ign it ion coil h a r n ess a n d (6) In st a ll t h e oil fill t u be.
m ove a wa y fr om cylin der h ea d cover. (7) In st a ll P CV h ose.
(11) Rem ove r igh t r ea r br ea t h er t u be a n d filt er (8) In st a ll h ea t er h oses.
a ssem bly. (9) In st a ll a ir con dit ion in g com pr essor r et a in in g
(12) Rem ove cylin der h ea d cover r et a in in g bolt s. bolt s.
(13) Rem ove cylin der h ea d cover. (10) In st a ll a ccessor y dr ive belt (Refer t o 7 -
NOTE: The gasket may be used again, provided no INSTALLATION).
cuts, tears, or deformation has occurred. (11) F ill Coolin g syst em (Refer t o 7 - COOLING -
(12) In st a ll a ir clea n er a ssem bly, r eson a t or a ssem -
CLEANING bly a n d a ir in let h ose.
Clea n cylin der h ea d cover ga sket su r fa ce. (13) Con n ect ba t t er y n ega t ive ca ble.
Clea n h ea d r a il, if n ecessa r y.
INSTALLATION—RIGHT SIDE I N TAK E/EX H AU ST VALV ES &

SEAT S
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers DESCRIPTION
may occur.
Th e va lves a r e m a de of h ea t r esist a n t st eel a n d
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. E a ch
CAUTION: DO NOT allow other components includ- va lve is a ct u a t ed by a r oller r ocker a r m wh ich pivot s
ing the wire harness to rest on or against the on a st a t ion a r y la sh a dju st er. All va lves u se t h r ee
engine cylinder head cover. Prolonged contact with bea d lock keeper s t o r et a in t h e spr in gs a n d pr om ot e
other objects may wear a hole in the cylinder head va lve r ot a t ion .
cover.
(1) Clea n cylin der h ea d cover a n d bot h sea lin g su r-

fa ces. In spect a n d r epla ce ga sket a s n ecessa r y.
STANDARD PROCEDURE—REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is

important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usin g a su it a ble dia l in dica t or m ea su r e t h e

cen t er of t h e va lve sea t Tot a l r u n ou t m u st n ot
exceed 0.051 m m (0.002 in ).
(2) Apply a sm a ll a m ou n t of P r u ssia n blu e t o t h e
va lve sea t , in ser t t h e va lve in t o t h e cylin der h ea d,
wh ile a pplyin g ligh t pr essu r e on t h e va lve r ot a t e t h e
va lve. Rem ove t h e va lve a n d exa m in e t h e va lve fa ce.
If t h e blu e is t r a n sfer r ed below t h e t op edge of t h e
va lve fa ce, lower t h e va lve sea t u sin g a 15 degr ee
st on e. If t h e blu e is t r a n sfer r ed t o t h e bot t om edge of Fig. 39 Valve Assembly Configuration
t h e va lve fa ce, r a ise t h e va lve sea t u sin g a 65 degr ee 1 - VALVE LOCKS (3–BEAD)
st on e. 2 - RETAINER
(3) Wh en t h e sea t is pr oper ly posit ion ed t h e widt h 3 - VALVE STEM OIL SEAL
of t h e in t a ke sea t m u st be 1.75 – 2.36 m m (0.0689 – 4 - INTAKE VALVE
0.0928 in .) a n d t h e exh a u st sea t m u st be 1.71 – 2.32 5 - EXHAUST VALVE
m m (0.0673 – 0.0911 in .). 6 - VALVE SPRING
(4) Ch eck t h e va lve spr in g in st a lled h eigh t a ft er
r efa cin g t h e va lve a n d sea t . Th e in st a lled h eigh t for
bot h in t a ke a n d exh a u st va lve spr in gs m u st n ot
exceed 41.44 m m (1.6315 in .) .
(5) Th e va lve sea t a n d va lve fa ce m u st m a in t a in a
fa ce a n gle of 44.5 – 45 degr ees a n gle (F ig. 39).
REMOVAL
NOTE: The cylinder heads must be removed in
order to preform this procedure.
(1) Usin g Specia l Tool 8516 Va lve Spr in g Com pr es-

sor, r em ove t h e r ocker a r m s a n d t h e h ydr a u lic la sh
a dju st er s (F ig. 40).
(2) Rem ove t h e ca m sh a ft bea r in g ca ps a n d t h e
ca m sh a ft .
NOTE: All eight valve springs and valves are

removed in the same manner; this procedure only
covers one valve and valve spring.
(3) Usin g Specia l Tool C-3422–B or C-3422–C

Va lve Spr in g Com pr essor a n d Specia l t ool 8519
Ada pt er, com pr ess t h e va lve spr in g. Fig. 40 Rocker Arm Removal
1 - CAMSHAFT
NOTE: It may be necessary to tap the top of the 2 - SPECIAL TOOL 8516
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Rem ove t h e t wo spr in g r et a in er lock h a lves.
NOTE: the valve spring is under tension use care

when releasing the valve spring compressor.
(5) Rem ove t h e va lve spr in g com pr essor.

(6) Rem ove t h e spr in g r et a in er, a n d t h e spr in g.
NOTE: Check for sharp edges on the keeper

grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Rem ove t h e va lve fr om t h e cylin der h ea d.
NOTE: The valve stem seals are common between

intake and exhaust.
(8) Rem ove t h e va lve st em sea l. Ma r k t h e va lve for Fig. 41 Testing Valve Springs
pr oper in st a lla t ion . 1 - SPECIAL TOOL C-647
TESTING VALVE SPRINGS

NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
In spect t h e va lve spr in gs for ph ysica l sign s of wea r

or da m a ge. Tu r n t a ble of t ool C-647 u n t il su r fa ce is
in lin e wit h t h e 40.69 m m (1.602 in .) m a r k on t h e
t h r ea ded st u d a n d t h e zer o m a r k on t h e fr on t . P la ce
spr in g over t h e st u d on t h e t a ble a n d lift com pr ess-
in g lever t o set t on e device. P u ll on t or qu e wr en ch
u n t il P in g is h ea r d. Ta ke r ea din g on t or qu e wr en ch
a t t h is in st a n t . Mu lt iply t h is r ea din g by t wo. Th is
will give t h e spr in g loa d a t t est len gt h . F r a ct ion a l
m ea su r em en t s a r e in dica t ed on t h e t a ble for fin er
a dju st m en t s. Refer t o Specifica t ion s Sect ion t o obt a in
specified h eigh t a n d a llowa ble t en sion s. Repla ce a n y
spr in gs t h a t do n ot m eet specifica t ion s. (F ig. 41)
INSTALLATION
(1) coa t t h e va lve st em wit h clea n en gin e oil a n d
in ser t it in t o t h e cylin der h ea d. Fig. 42 Valve Assembly Configuration
(2) In st a ll t h e va lve st em sea l. m a ke su r e t h e sea l 1 - VALVE LOCKS (3–BEAD)
is fu lly sea t ed a n d t h a t t h e ga r t er spr in g a t t h e t op 2 - RETAINER
of t h e sea l is in t a ct . 3 - VALVE STEM OIL SEAL
(3) Insta ll the spring a nd the spring reta iner (Fig. 42). 4 - INTAKE VALVE
(4) Usin g t h e va lve spr in g com pr essor, com pr ess 5 - EXHAUST VALVE
t h e spr in g a n d in st a ll t h e t wo va lve spr in g r et a in er 6 - VALVE SPRING
h a lves.
(5) Relea se t h e va lve spr in g com pr essor a n d m a ke
su r e t h e t wo spr in g r et a in er h a lves a n d t h e spr in g
r et a in er a r e fu lly sea t ed.
(6) lu br ica t e t h e ca m sh a ft jou r n a l wit h clea n
en gin e oil t h en P osit ion t h e ca m sh a ft (wit h t h e
spr ocket dowel on t h e left ca m sh a ft a t 11 o’clock a n d
t h e r igh t ca m sh a ft a t 12 o’clock), t h en posit ion t h e
ca m sh a ft bea r in g ca ps.
(7) In st a ll t h e ca m sh a ft bea r in g ca p r et a in in g (4) F or r ocker a r m r em ova l on cylin der s 4 a n d 6
bolt s. Tigh t en t h e bolt s 9–13 N·m (100 in . lbs.) in 1 ⁄2 Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
t u r n in cr em en t s in t h e sequ en ce sh own (F ig. 43). com pr ession st r oke.
(6) Usin g specia l t ool 8516 pr ess down wa r d on t h e
va lve spr in g, r em ove r ocker a r m (F ig. 44).
Fig. 43 Camshaft Bearing Caps Tightening

Sequence
(8) P osit ion t h e h ydr a u lic la sh a dju st er s and
r ocker a r m s (F ig. 24).
Fig. 44 Rocker Arm—Removal

ROCK ER ARM / ADJ U ST ER 1 - CAMSHAFT
ASSEM BLY 2 - SPECIAL TOOL 8516
DESCRIPTION INSTALLATION
Th e r ocker a r m s a r e st eel st a m pin gs wit h a n in t e-
gr a l r oller bea r in g. Th e r ocker a r m s in cor por a t e a 2.8 CAUTION: Make sure the rocker arms are installed
m m (0.11 in ch ) oil h ole in t h e la sh a dju st er socket for with the concave pocket over the lash adjusters.
r oller a n d ca m sh a ft lu br ica t ion . Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
REMOVAL
NOTE: Disconnect the battery negative cable to pre- NOTE: Coat the rocker arms with clean engine oil
vent accidental starter engagement. prior to installation.
(1) Rem ove t h e cylin der h ea d cover. Refer t o Cyl- (1) F or r ocker a r m in st a lla t ion on cylin der s 3 a n d
in der H ea d Cover in t h is sect ion . 5 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
(2) F or r ocker a r m r em ova l on cylin der s 3 a n d 5 exh a u st st r oke.
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC (2) F or r ocker a r m in st a lla t ion on cylin der s 2 a n d
exh a u st st r oke. 8 Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC
(3) F or r ocker a r m r em ova l on cylin der s 2 a n d 8 com pr ession st r oke.
Rot a t e t h e cr a n ksh a ft u n t il cylin der #1 is a t TDC (3) F or r ocker a r m in st a lla t ion on cylin der s 4 a n d
com pr ession st r oke. 6 Rot a t e t h e cr a n ksh a ft u n t il cylin der #3 is a t TDC
(4) F or r ocker a r m in st a lla t ion on cylin der s 1 a n d (2) Degla zin g of t h e cylin der wa lls m a y be don e if
7 Rot a t e t h e cr a n ksh a ft u n t il cylin der #2 is a t TDC t h e cylin der bor e is st r a igh t a n d r ou n d. Use a cylin -
com pr ession st r oke. der su r fa cin g h on e, H on in g Tool C-3501, equ ipped
(5) Usin g specia l t ool 8516 pr ess down wa r d on t h e wit h 280 gr it st on es (C-3501-3810). a bou t 20-60
va lve spr in g, in st a ll r ocker a r m (F ig. 28). st r okes, depen din g on t h e bor e con dit ion , will be su f-
(6) In st a ll t h e cylin der h ea d cover. ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Usin g h on in g
oil C-3501-3880, or a ligh t h on in g oil, a va ila ble fr om
m a jor oil dist r ibu t or s.
VALV E SPRI N GS
CAUTION: DO NOT use engine or transmission oil,
DESCRIPTION mineral spirits, or kerosene.
Th e va lve spr in gs a r e m a de fr om h igh st r en gt h
ch r om e silicon st eel. Th e spr in gs a r e com m on for (3) H on in g sh ou ld be don e by m ovin g t h e h on e u p
in t a ke a n d exh a u st a pplica t ion s. Th e va lve spr in g a n d down fa st en ou gh t o get a cr ossh a t ch pa t t er n .
sea t is in t egr a l wit h t h e va lve st em sea l, wh ich is a Th e h on e m a r ks sh ou ld INTE RSE CT a t 50° t o 60°
posit ive t ype sea l t o con t r ol lu br ica t ion . for pr oper sea t in g of r in gs (F ig. 45).
VALV E ST EM SEALS
DESCRIPTION
Th e va lve st em sea ls a r e m a de of r u bber a n d in cor-
por a t e a n in t egr a l st eel va lve spr in g sea t . Th e in t e-
gr a l ga r t er spr in g m a in t a in s con sist en t lu br ica t ion
con t r ol t o t h e va lve st em s.
EN GI N E BLOCK
DESCRIPTION
Th e cylin der block is m a de of ca st ir on . Th e block
is a closed deck design wit h t h e left ba n k for wa r d. To
pr ovide h igh r igidit y a n d im pr oved NVH a n Fig. 45 Cylinder Bore Crosshatch Pattern
en h a n ced com pa ct ed gr a ph it e bedpla t e is bolt ed t o 1 - CROSSHATCH PATTERN
t h e block. Th e block design a llows coola n t flow 2 - INTERSECT ANGLE
bet ween t h e cylin der s bor es, a n d a n in t er n a l coola n t
bypa ss t o a sin gle poppet in let t h er m ost a t is in clu ded (4) A con t r olled h on e m ot or speed bet ween 200 a n d
in t h e ca st a lu m in u m fr on t cover. 300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss-
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per
STANDARD PROCEDURE—CYLINDER BORE m in u t e ca n be r egu la t ed t o get t h e desir ed 50° t o 60°
HONING a n gle. F a st er u p a n d down st r okes in cr ea se t h e cr oss-
Befor e h on in g, st u ff plen t y of clea n sh op t owels h a t ch a n gle.
u n der t h e bor es a n d over t h e cr a n ksh a ft t o keep (5) Aft er h on in g, it is n ecessa r y t h a t t h e block be
a br a sive m a t er ia ls fr om en t er in g t h e cr a n ksh a ft clea n ed t o r em ove a ll t r a ces of a br a sive. Use a br u sh
a r ea . t o wa sh pa r t s wit h a solu t ion of h ot wa t er a n d det er-
(1) Used ca r efu lly, t h e Cylin der Bor e Sizin g H on e gen t . Dr y pa r t s t h or ou gh ly. Use a clea n , wh it e, lin t -
C-823, equ ipped wit h 220 gr it st on es, is t h e best t ool fr ee clot h t o ch eck t h a t t h e bor e is clea n . Oil t h e
for t h is job. In a ddit ion t o degla zin g, it will r edu ce bor es a ft er clea n in g t o pr even t r u st in g.
t a per a n d ou t -of-r ou n d, a s well a s r em ovin g ligh t
scu ffin g, scor in g a n d scr a t ch es. Usu a lly, a few st r okes CLEANING
will clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim - Th or ou gh ly clea n t h e oil pa n a n d en gin e block ga s-
it s. ket su r fa ces.
Use com pr essed a ir t o clea n ou t :
CAUTION: DO NOT use rigid type hones to remove • Th e ga lley a t t h e oil filt er a da pt or h ole.
cylinder wall glaze. • Th e fr on t a n d r ea r oil ga lley h oles.
• Th e feed h oles for t h e cr a n ksh a ft m a in bea r in gs.
EN GI N E BLOCK (Cont inue d)
On ce t h e block h a s been com plet ely clea n ed, a pply (7) If cylin der bor e t a per does n ot exceed 0.025
Loct it e P ST pipe sea la n t wit h Teflon 592 t o t h e m m (0.001 in ch ) a n d ou t -of-r ou n dn ess does n ot
t h r ea ds of t h e fr on t a n d r ea r oil ga lley plu gs. Tigh t en exceed 0.025 m m (0.001 in ch ), t h e cylin der bor e ca n
t h e plu gs t o 34 N·m (25 ft . lbs.) t or qu e. be h on ed. If t h e cylin der bor e t a per or ou t - of-r ou n d
con dit ion exceeds t h ese m a xim u m lim it s, t h e cylin der
INSPECTION block m u st be r epla ced. A sligh t a m ou n t of t a per
(1) It is m a n da t or y t o u se a dia l bor e ga u ge t o a lwa ys exist s in t h e cylin der bor e a ft er t h e en gin e
m ea su r e ea ch cylin der bor e dia m et er. To cor r ect ly h a s been in u se for a per iod of t im e.
select t h e pr oper size pist on , a cylin der bor e ga u ge,
ca pa ble of r ea din g in 0.003 m m (.0001 in .) INCRE -
ME NTS is r equ ir ed. If a bor e ga u ge is n ot a va ila ble, CON N ECT I N G ROD BEARI N GS
do n ot u se a n in side m icr om et er (F ig. 46).
STANDARD PROCEDURE—CONNECTING ROD
BEARING FITTING
In spect t h e con n ect in g r od bea r in gs for scor in g a n d
ben t a lign m en t t a bs (F ig. 47) (F ig. 48). Ch eck t h e
bea r in gs for n or m a l wea r pa t t er n s, scor in g, gr oovin g,
fa t igu e a n d pit t in g (F ig. 49). Repla ce a n y bea r in g
t h a t sh ows a bn or m a l wea r.
In spect t h e con n ect in g r od jou r n a ls for sign s of
scor in g, n icks a n d bu r r s.
Fig. 46 Bore Gauge—Typical

1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 49.5 MM
(1–15/16 in)

bor e a t t h r ee levels below t op of bor e. St a r t per pen -
dicu la r (a cr oss or a t 90 degr ees) t o t h e a xis of t h e
cr a n ksh a ft a n d t h en t a ke t wo a ddit ion a l r ea din g. Fig. 47 Connecting Rod Bearing Inspection
(3) Mea su r e t h e cylin der bor e dia m et er cr osswise 1 - UPPER BEARING HALF
t o t h e cylin der block n ea r t h e t op of t h e bor e. Repea t 2 - MATING EDGES
t h e m ea su r em en t n ea r t h e m iddle of t h e bor e, t h en 3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
r epea t t h e m ea su r em en t n ea r t h e bot t om of t h e bor e. 4 - WEAR PATTERN — ALWAYS GREATER ON UPPER
(4) Det er m in e t a per by su bt r a ct in g t h e sm a ller BEARING
dia m et er fr om t h e la r ger dia m et er. 5 - LOWER BEARING HALF
(5) Rot a t e m ea su r in g device 90° a n d r epea t st eps
a bove. Misa lign ed or ben t con n ect in g r ods ca n ca u se
(6) Det er m in e ou t -of-r ou n dn ess by com pa r in g t h e a bn or m a l wea r on pist on s, pist on r in gs, cylin der
differ en ce bet ween ea ch m ea su r em en t . wa lls, con n ect in g r od bea r in gs a n d cr a n ksh a ft con -
n ect in g r od jou r n a ls. If wea r pa t t er n s or da m a ge t o
Fig. 48 Locking Tab Inspection

1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 50 Piston and Connecting Rod—Installation

Fig. 49 Scoring Caused by Insufficient Lubrication 1 - “F” TOWARD FRONT OF ENGINE
or Damaged Crankshaft Journal 2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
a n y of t h ese com pon en t s in dica t e t h e pr oba bilit y of a
m isa lign ed con n ect in g r od, in spect it for cor r ect r od
a lign m en t . Repla ce m isa lign ed, ben t or t wist ed con -
n ect in g r ods. (6) Rem ove t h e bea r in g ca p a n d det er m in e a m ou n t
(1) Wipe t h e oil fr om t h e con n ect in g r od jou r n a l. of bea r in g-t o-jou r n a l clea r a n ce by m ea su r in g t h e
(2) Lu br ica t e t h e u pper bea r in g in ser t a n d in st a ll widt h of com pr essed P la st iga ge (F ig. 51). Refer t o
in con n ect in g r od. E n gin e Specifica t ion s for t h e pr oper clea r a n ce. P la s -
(3) Use pist on r in g com pr essor a n d Gu ide P in s tig a g e s h o u ld in d ic a te th e s a m e c le a ra n c e
Specia l Tool 8507 (F ig. 50) t o in st a ll t h e r od a n d pis- a c ro s s th e e n tire w id th o f th e in s e rt. If th e
t on a ssem blies. Th e oil slin ger slot s in t h e r ods m u st c le a ra n c e v a rie s , it m a y be c a u s e d by e ith e r a
fa ce fr on t of t h e en gin e. Th e “F ” ’s n ea r t h e pist on ta p e re d jo u rn a l, be n t c o n n e c tin g ro d o r fo re ig n
wr ist pin bor e sh ou ld poin t t o t h e fr on t of t h e en gin e. m a te ria l tra p p e d be tw e e n th e in s e rt a n d c a p o r
(4) In st a ll t h e lower bea r in g in ser t in t h e bea r in g ro d .
ca p. Th e lower in ser t m u st be dr y. P la ce st r ip of P la s- (7) If t h e cor r ect clea r a n ce is in dica t ed, r epla ce-
t iga ge a cr oss fu ll widt h of t h e lower in ser t a t t h e cen - m en t of t h e bea r in g in ser t s is n ot n ecessa r y. Rem ove
t er of bea r in g ca p. P la st iga ge m u st n ot cr u m ble in t h e P la st iga ge fr om cr a n ksh a ft jou r n a l a n d bea r in g
u se. If br it t le, obt a in fr esh st ock. in ser t . P r oceed wit h in st a lla t ion .
(5) In st a ll bea r in g ca p a n d con n ect in g r od on t h e (8) If bea r in g-t o-jou r n a l clea r a n ce exceeds t h e
jou r n a l a n d t igh t en bolt s t o 27 N·m (20 ft . lbs.) plu s a specifica t ion , det er m in wh ich ser vices bea r in g set t o
90° t u r n . DO NOT r ot a t e cr a n ksh a ft . P la st iga ge will u se t h e bea r in g sizes a r e a s follows:
sm ea r, r esu lt in g in in a ccu r a t e in dica t ion .
Fig. 51 Measuring Bearing Clearance with Fig. 52 Checking Connecting Rod Side Clearance—
Plastigage Typical
1 - PLASTIGAGE SCALE a r e cr oss dr illed t o im pr ove r od bea r in g lu br ica t ion .
2 - COMPRESSED PLASTIGAGE Th e n u m ber eigh t cou n t er weigh t h a s pr ovision s for
cr a n ksh a ft posit ion sen sor t a r get wh eel m ou n t in g.
Th e select fit m a in bea r in g m a r kin gs a r e loca t ed on
Bearing SIZE USED WITH
t h e r ea r side of t h e t a r get wh eel. Th e cr a n ksh a ft oil
Mark
sea ls a r e on e piece design . Th e fr on t oil sea l is
JOURNAL SIZE r et a in ed in t h e t im in g ch a in cover, a n d t h e r ea r sea l
is pr essed in t o a bor e for m ed by t h e cylin der block
.025 US .025 mm 50.983-50.967 mm
a n d t h e bedpla t e a ssem bly.
(.001 in.) (2.0073-2.0066 in.)
Std. STANDARD 50.992-51.008 mm

STANDARD PROCEDURE - CRANKSHAFT END
(2.0076-2.0082 in.)
PLAY
(1) Mou n t a dia l in dica t or t o fr on t of en gin e wit h
.250 US .250 mm 50.758-50.742 mm t h e loca t in g pr obe on n ose of cr a n ksh a ft (F ig. 53).
(2) Move cr a n ksh a ft a ll t h e wa y t o t h e r ea r of it s
(.010 in.) (1.9984-1.9978 in.)
t r a vel.
(3) Zer o t h e dia l in dica t or.
(9) Repea t t h e P la st iga ge m ea su r em en t t o ver ify (4) Move cr a n ksh a ft a ll t h e wa y t o t h e fr on t a n d
you r bea r in g select ion pr ior t o fin a l a ssem bly. r ea d t h e dia l in dica t or. (Refer t o 9 - E NGINE -
(10) On ce you h a ve select ed t h e pr oper in ser t , SP E CIF ICATIONS) for en d pla y specifica t ion .
in st a ll t h e in ser t a n d ca p. Tigh t en t h e con n ect in g r od
bolt s t o 27 N·m (20 ft . lbs.) plu s a 90° t u r n .
Slide sn u g-fit t in g feeler ga u ge bet ween t h e con -
n ect in g r od a n d cr a n ksh a ft jou r n a l fla n ge (F ig. 52).
Refer t o E n gin e Specifica t ion s for t h e pr oper clea r-
a n ce. Repla ce t h e con n ect in g r od if t h e side clea r a n ce
is n ot wit h in specifica t ion .
CRAN K SH AFT
DESCRIPTION
Th e cr a n ksh a ft is con st r u ct ed of n odu la r ca st ir on .
Th e cr a n ksh a ft is a cr ossh a ped fou r t h r ow design
wit h eigh t cou n t er weigh t s for ba la n cin g pu r poses.
Th e cr a n ksh a ft is su ppor t ed by five select fit m a in
bea r in gs wit h t h e n u m ber t h r ee ser vin g a s t h e t h r u st
wa sh er loca t ion . Th e m a in jou r n a ls of t h e cr a n ksh a ft Fig. 53 Checking Crankshaft End Play—Typical
CRAN K SH AFT (Cont inue d)
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Rem ove t h e en gin e. (Refer t o 9 - E NGINE -

RE MOVAL).
(2) Rem ove t h e en gin e oil pu m p.(Refer t o 9 -
E NGINE /LUBRICATION/OIL P UMP - RE MOVAL).
CAUTION: DO NOT pry on the oil pan gasket when

removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-

CATION/OIL PAN - RE MOVAL).
(4) Rem ove t h e oil pu m p picku p t u be a n d oil pa n
ga sket /win da ge t r a y.
(5) Rem ove t h e bedpla t e m ou n t in g bolt s. Not e t h e
loca t ion of t h e t h r ee st u d bolt s for in st a lla t ion .
(6) Rem ove t h e con n ect in g r ods fr om t h e cr a n k-
sh a ft .
CAUTION: The bedplate to cylinder block mating Fig. 54 Bedplate Pry Point Location
surface is a critical sealing surface. Do not pry on 1 - CYLINDER BLOCK
or damage this surface in anyway. 2 - BEDPLATE
3 - PRY POINT
NOTE: The bedplate contains the lower main bear-

If con n ect in g r od bea r in g bor es sh ow da m a ge, t h e
ing halves. Use care when handling bedplate as not
cylin der h ea ds m u st be r em oved t o ser vice t h e pist on
to drop or damage bearing halves. Installing main
a n d r od a ssem blies. If t h e bedpla t e or t h e cylin der
bearing halves in the wrong position will cause
block m a in bea r in g bor es sh ow da m a ge t h e en gin e
sever damage to the crankshaft.
m u st be r epla ced.
(1) If r equ ir ed, r em ove t h e m a in bea r in g h a lves
NOTE: The bedplate has pry points cast into it. Use fr om t h e cylin der block a n d bedpla t e.
these points only. The pry points are on both the (2) Th or ou gh ly clea n t h e bedpla t e t o cylin der block
left and right sides, only the left side is shown. sea lin g su r fa ces a n d m a in bea r in g bor es. Rem ove a ll
oil a n d sea la n t r esidu e.
(7) Ca r efu lly pr y on t h e pr y poin t s (F ig. 54) t o (3) In spect t h e bedpla t e m a in bea r in g bor es for
loosen t h e bedpla t e t h en r em ove t h e bedpla t e. cr a cks, scor in g or sever e blu ein g. If eit h er con dit ion
exist s t h e en gin e m u st be r epla ced.
CAUTION: When removing the crankshaft, use care (4) In spect t h e cr a n ksh a ft t h r u st wa sh er for scor-
not to damage bearing surfaces on the crankshaft. in g, scr a t ch es or blu ein g. If eit h er con dit ion exist
r epla ce t h e t h r u st wa sh er.
(8) Rem ove t h e cr a n ksh a ft . (5) In spect t h e oil pa n ga sket /win da ge t r a y for
(9) Rem ove t h e cr a n ksh a ft t a r get wh eel. split s, t ea r s or cr a cks in t h e ga sket sea lin g su r fa ces.
Repla ce ga sket a s n ecessa r y.
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
INSTALLATION
ing bores and main bearing bores for scoring, blue- CAUTION: Main bearings are select fit. (Refer to 9 -
ing or severe scratches. Further disassembly may ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
be required. BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
(1) Lu br ica t e u pper m a in bea r in g h a lves wit h
clea n en gin e oil.
CAUTION: When installing crankshaft, use care not

to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the target wheel retaining

screws prior to installation.
(2) In st a ll t h e cr a n ksh a ft t a r get wh eel. Tor qu e t h e

m ou n t in g scr ews t o 22 N·m (21 ft . lbs.).
(3) P osit ion cr a n ksh a ft in cylin der block.
(4) In st a ll t h e t h r u st wa sh er s (F ig. 55).
Fig. 56 Cutting Aplicator to Achieve 2.5mm (0.100

in.) Bead
1 - CUT HERE
Fig. 55 Crankshaft Thrust Washer Installation

1 - CRANKSHAFT THRUST WASHER
CAUTION: The bedplate to cylinder block mateing

surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks. Fig. 57 Cylinder Block-to-Bedplate Sealent Bead
Location
1 - CYLINDER BLOCK
NOTE: The installation time to install the bedplate
2 - SEALANT BEAD LOCATION
after the sealant has been applied is critical.
(6) Coa t t h e cr a n ksh a ft m a in bea r in g jou r n a ls

NOTE: Make sure that the bedplate and cylinder wit h clea n en gin e oil a n d posit ion t h e bedpla t e on t o
block sealing surfaces are clean and free of oil or t h e cylin der block.
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or NOTE: Lubricate the bedplate retaining bolts with
oil leaks. clean engine oil prior to installation.
(5) Apply a 2.5m m (0.100 in ch ) (F ig. 56) bea d of (7) In st a ll t h e bedpla t e r et a in in g bolt s, m a kin g
Mopa r ! Gen II Silicon e Ru bber Adh esive sea la n t t o su r e t o pla ce t h e st u d bolt s in t h e cor r ect loca t ion ,
t h e cylin der block-t o-bedpla t e m a t in g su r fa ce a s Tor qu e t h e bolt s in t h e sequ en ce sh own (F ig. 58).
sh own (F ig. 57). • Tigh t en bolt s A – L t o 54 N·m (40 ft . lbs.)
• Tigh t en bolt s 1–10 t o 2.8 N·m (25 in . lbs.)
• Tu r n bolt s 1–10 a n a ddit ion a l 90°.
• Tigh t en bolt s A1– A6 t o 27 N·m (20 ft . lbs.)
Fig. 58 Bedplate Tightening Sequence

1 - BEDPLATE
2 - CYLINDER BLOCK
(8) Mea su r e cr a n ksh a ft en d pla y. (Refer t o 9 -

E NGINE /E NGINE BLOCK/CRANKSH AF T - STAN-
DARD P ROCE DURE ).
(9) In st a ll t h e con n ect in g r ods a n d m ea su r e side
clea r a n ce. (Refer t o 9 - E NGINE /E NGINE BLOCK/
CONNE CTING ROD BE ARINGS - STANDARD
P ROCE DURE ).
(10) P osit ion t h e oil pa n ga sket /win da ge t r a y,
u sin g a n ew o-r in g, in st a ll t h e oil picku p t u be.
Tor qu e t h e bolt t o 28N·n (20 ft . lbs.) t or qu e t h e n u t s
t o 28N·m (20 ft . lbs.).
(11) In st a ll t h e oil pa n . Tor qu e t h e r et a in in g bolt s
t o 15 N·m (11 ft . lbs.) in t h e sequ en ce sh own (F ig.
59). Fig. 59 Oil Pan Tightening Sequence
(12) In st a ll t h e en gin e (Refer t o 9 - E NGINE -
INSTALLATION).
CRAN K SH AFT M AI N NOTE: Service main bearings are coded. These

codes identify what size (grade) the bearing is.
BEARI N GS
M AI N BEARI N G SELECT I ON CH ART —4 .7 L
STANDARD PROCEDURE—CRANKSHAFT MAIN
BEARING - FITTING GRADE SIZE mm FOR USE WITH
(in.)
MAIN BEARING JOURNAL DIAMETER MARKING JOURNAL SIZE
(CRANKSHAFT REMOVED)
Cr a n ksh a ft r em oved fr om t h e cylin der block. A 0.008 mm 63.488–63.496 mm
Clea n t h e oil off t h e m a in bea r in g jou r n a l. U/S
Det er m in e t h e m a xim u m dia m et er of t h e jou r n a l (0.0004 in.) (2.4996–2.4999 in.)
wit h a m icr om et er. Mea su r e a t t wo loca t ion s 90° U/S
a pa r t a t ea ch en d of t h e jou r n a l.
Th e m a xim u m a llowa ble t a per is 0.008m m (0.0004 B NOMINAL 63.496–63.504 mm
in ch .) a n d m a xim u m ou t of r ou n d is 0.005m m (0.002 (2.4999–2.5002 in.)
in ch ). Com pa r e t h e m ea su r ed dia m et er wit h t h e jou r-
n a l dia m et er specifica t ion (Ma in Bea r in g F it t in g C 0.008 mm 63.504–63.512 mm
Ch a r t ). Select in ser t s r equ ir ed t o obt a in t h e specified O/S
bea r in g-t o-jou r n a l clea r a n ce. (0.0004 in.) (2.5002–2.5005 in.)
O/S
CRANKSHAFT MAIN BEARING SELECTION
Th e m a in bea r in gs a r e “select fit ” t o a ch ieve pr oper INSPECTION
oil clea r a n ces. F or m a in bea r in g select ion , t h e cr a n k-
Wipe t h e in ser t s clea n a n d in spect for a bn or m a l
sh a ft posit ion sen sor t a r get wh eel h a s gr a de iden t ifi-
wea r pa t t er n s a n d for m et a l or ot h er for eign m a t er ia l
ca t ion m a r ks st a m ped in t o it (F ig. 60). Th ese m a r ks
im bedded in t h e lin in g. Nor m a l m a in bea r in g in ser t
a r e r ea d fr om left t o r igh t , cor r espon din g wit h jou r-
wea r pa t t er n s a r e illu st r a t ed (F ig. 61).
n a l n u m ber 1, 2, 3, 4 a n d 5. Th e cr a n ksh a ft posit ion
sen sor t a r get wh eel is m ou n t ed t o t h e n u m ber 8
cou n t er weigh t on t h e cr a n ksh a ft .
Fig. 61 Main Bearing Wear Patterns

1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
Fig. 60 Main Bearing Markings on Target Wheel NOTE: If any of the crankshaft journals are scored,
1 - REARMOST CRANKSHAFT COUNTER WEIGHT the crankshaft must be repaired or replaced.
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS In spect t h e ba ck of t h e in ser t s for fr a ct u r es, scr a p-
in gs or ir r egu la r wea r pa t t er n s.
In spect t h e u pper in ser t lockin g t a bs for da m a ge.
Repla ce a ll da m a ged or wor n bea r in g in ser t s. (11) Usin g Specia l Tool 8511, r em ove cr a n ksh a ft
fr on t sea l (F ig. 63).
CRAN K SH AFT OI L SEAL -

FRON T
REMOVAL
(2) Rem ove a ccessor y dr ive belt (Refer t o 7 -
RE MOVAL).
(3) Rem ove A/C com pr essor m ou n in g fa st en er s a n d
set a side.
(5) Rem ove u pper r a dia t or h ose.
(6) Discon n ect elect r ica l con n ect or for fa n m ou n t ed
in side r a dia t or sh r ou d.
(7) Rem ove r a dia t or sh r ou d a t t a ch in g fa st en er s.
NOTE: Transmission cooler line snaps into shroud

lower right hand corner.
(8) Rem ove r a dia t or coolin g fa n a n d sh r ou d (Refer

t o 7 - COOLING/E NGINE /RADIATOR FAN - Fig. 63 Crankshaft Front Seal—Removal
RE MOVAL). 1 - SPECIAL TOOL 8511
(9) Rem ove cr a n ksh a ft da m per bolt .
(10) Rem ove da m per u sin g Specia l Tools 8513
In ser t a n d 1026 Th r ee J a w P u ller (F ig. 62). INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
Fig. 62 Crankshaft Damper—Removal

1 - SPECIAL TOOL 8513 INSERT
CRAN K SH AFT OI L SEAL - FRON T (Cont inue d)
(1) Usin g Specia l Tool 8348 a n d 8512, in st a ll (2) Rem ove t h e flexpla t e (Refer t o 9 - E NGINE /
cr a n ksh a ft fr on t sea l (F ig. 64). E NGINE BLOCK/F LE X P LATE - RE MOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused

after removal.
NOTE: The crankshaft rear oil seal remover Special

Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usin g Specia l Tool 8506 (F ig. 65), r em ove t h e
cr a n ksh a ft r ea r oil sea l.
Fig. 64 Crankshaft Front Seal—Installation

1 - TIMING CHAIN COVER
(2) In st a ll vibr a t ion da m per (Refer t o 9 - E NGINE /

E NGINE BLOCK/VIBRATION DAMP E R - INSTAL-
LATION).
(3) In st a ll r a dia t or coolin g fa n a n d sh r ou d (Refer
t o 7 - COOLING/E NGINE /RADIATOR FAN - Fig. 65 Crankshaft Rear Oil Seal Removal
INSTALLATION). 1 - REAR CRANKSHAFT SEAL
(4) In st a ll u pper r a dia t or h ose. 2 - SPECIAL TOOL 8506
(5) In st a ll A/C com pr essor a n d t igh t en fa st en er s t o
54 N·m (40 ft . lbs.).
(6) In st a ll a ccessor y dr ive belt r efer (Refer t o 7 - INSTALLATION
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - (1) P osit ion t h e m a gn et ic sea l gu ide Specia l Tool
INSTALLATION). 8349–2 (F ig. 66) on t o t h e cr a n ksh a ft r ea r fa ce. Th en
(7) Refill coolin g syst em (Refer t o 7 - COOLING - posit ion t h e cr a n ksh a ft r ea r oil sea l on t o t h e gu ide.
STANDARD P ROCE DURE ). (2) Usin g Specia l Tools 8349 Cr a n ksh a ft Rea r Oil
(8) Con n ect n ega t ive ca ble t o ba t t er y. Sea l In st a ller a n d C-4171 Dr iver H a n dle (F ig. 67),
wit h a h a m m er, t a p t h e sea l in t o pla ce. Con t in u e t o
t a p on t h e dr iver h a n dle u n t il t h e sea l in st a ller sea t s
CRAN K SH AFT OI L SEAL - a ga in st t h e cylin der block cr a n ksh a ft bor e.
REAR (3) In st a ll t h e flexpla t e.
(4) If r em oved, in st a ll t h e t r a n sm ission .
REMOVAL
NOTE: This procedure can be preformed in vehicle. FLEX PLAT E
(1) If bein g pr efor m ed in veh icle, r em ove t h e
t r a n sm ission . REMOVAL
(1) Rem ove t h e t r a n sm ission .
(2) Rem ove t h e bolt s a n d flexpla t e.
FLEX PLAT E (Cont inue d)
Fig. 66 Crankshaft Rear Oil Seal Guide Special Tool

8349–2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349–2 GUIDE
Fig. 68 Flexplate Tightening Sequence
1 - FLEXPLATE
PI ST ON & CON N ECT I N G ROD

DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
Th e pist on s a r e m a de of a h igh st r en gt h a lu m in u m
a lloy. Th e a n odized t op r in g gr oove a n d cr own h a s
been r epla ced wit h a coa t ed t op r in g t h a t is blu e in
color. P ist on skir t s a r e coa t ed wit h a solid lu br ica n t
(Molykot e) t o r edu ce fr ict ion a n d pr ovide scu ff r esis-
t a n ce. Th e con n ect in g r ods a r e m a de of for ged pow-
der ed m et a l, wit h a “fr a ct u r ed ca p” design . A pr essed
fit pist on pin is u sed t o a t t a ch t h e pist on a n d con -
n ect in g r od.
Fig. 67 Crankshaft Rear Oil Seal Installation STANDARD PROCEDURE—PISTON FITTING

1 - REAR CRANKSHAFT SEAL (1) To cor r ect ly select t h e pr oper size pist on , a cyl-
2 - SPECIAL TOOL 8349–1 INSTALLER in der bor e ga u ge, ca pa ble of r ea din g in 0.003 m m
3 - SPECIAL TOOL C-4171 HANDLE (.0001 in .) INCRE ME NTS is r equ ir ed. If a bor e
ga u ge is n ot a va ila ble, do n ot u se a n in side m icr om e-
t er.
INSTALLATION
(1) P osit ion t h e flexpla t e on t o t h e cr a n ksh a ft a n d
bor e a t a poin t 49.5 m m (1-15/16 in ch es) below t op of
in st a ll t h e bolt s h a n d t igh t .
bor e. St a r t per pen dicu la r (a cr oss or a t 90 degr ees) t o
(2) Tigh t en t h e flexpla t e r et a in in g bolt s t o 60 N·m
t h e a xis of t h e cr a n ksh a ft a t poin t A a n d t h en t a ke
(45 ft . lbs.) in t h e sequ en ce sh own (F ig. 68).
a n a ddit ion a l bor e r ea din g 90 degr ees t o t h a t a t poin t
(3) In st a ll t h e t r a n sm ission .
B (F ig. 70).
(3) Th e coa t ed pist on s will be ser viced wit h t h e
pist on pin a n d con n ect in g r od pr e-a ssem bled. Tin
coa t ed pist on s sh ou ld n ot be u sed a s r epla cem en t s for
coa t ed pist on s.
(4) Th e coa t in g m a t er ia l is a pplied t o t h e pist on
a ft er t h e fin a l pist on m a ch in in g pr ocess. Mea su r in g
t h e ou t side dia m et er of a coa t ed pist on will n ot pr o-
vide a ccu r a t e r esu lt s (F ig. 69). Th er efor e m ea su r in g
t h e in side dia m et er of t h e cylin der bor e wit h a dia l
Bor e Ga u ge is MAN D ATORY. To cor r ect ly select t h e
pr oper size pist on , a cylin der bor e ga u ge ca pa ble of
r ea din g in 0.003 m m (.0001 in .) in cr em en t s is
r equ ir ed.
(5) P ist on in st a lla t ion in t o t h e cylin der bor e
r equ ir es sligh t ly m or e pr essu r e t h a n t h a t r equ ir ed
for n on -coa t ed pist on s. Th e bon ded coa t in g on t h e
pist on will give t h e a ppea r a n ce of a lin e-t o-lin e fit
wit h t h e cylin der bor e.
Fig. 70 Bore Gauge—Typical

1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 49.5 MM
(1–15/16 in)
fr om cylin der block. B e s u re to k e e p to p s o f p is -

to n s c o v e re d d u rin g th is o p e ra tio n . P ist on s a n d
con n ect in g r ods m u st be r em oved fr om t op of cylin der
block. Wh en r em ovin g pist on a n d con n ect in g r od
a ssem blies fr om t h e en gin e, r ot a t e cr a n ksh a ft so t h e
ea ch con n ect in g r od is cen t er ed in cylin der bor e.
Fig. 69 Moly Coated Piston
CAUTION: DO NOT use a number stamp or a punch
1 - MOLY COATED
2 - MOLY COATED
to mark connecting rods or caps, as damage to
connecting rods could occur
REMOVAL
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
(2) Rem ove t h e followin g com pon en t s:
removing to ensure correct reassembly.
• Oil pa n a n d ga sket /win da ge t r a y (Refer t o 9 -
E NGINE /LUBRICATION/OIL PAN - RE MOVAL). (4) Ma r k con n ect in g r od a n d bea r in g ca p posit ion s
• Cylin der h ea d cover s (Refer t o 9 - E NGINE / u sin g a per m a n en t in k m a r ker or scr ibe t ool (F ig.
CYLINDE R H E AD/CYLINDE R H E AD COVE R(S) - 71).
RE MOVAL) a n d (Refer t o 9 - E NGINE /CYLINDE R
H E AD/CYLINDE R H E AD COVE R(S) - RE MOVAL). CAUTION: Care must be taken not to damage the
• Tim in g ch a in cover (Refer t o 9 - E NGINE / fractured rod and cap joint face surfaces, as engine
VALVE TIMING/TIMING BE LT / CH AIN COVE R(S) damage may occur.
- RE MOVAL).
• Cylin der h ea d(s) (Refer t o 9 - E NGINE /CYLIN- (5) Rem ove con n ect in g r od ca p. In st a ll Specia l Tool
DE R H E AD - RE MOVAL) a n d (Refer t o 9 - E NGINE / 8507 Con n ect in g Rod Gu ides in t o t h e con n ect in g r od
CYLINDE R H E AD - RE MOVAL). bein g r em oved. Rem ove pist on fr om cylin der bor e.
(3) If n ecessa r y, r em ove t op r idge of cylin der bor es Repea t t h is pr ocedu r e for ea ch pist on bein g r em oved.
wit h a r elia ble r idge r ea m er befor e r em ovin g pist on s
INSTALLATION
(1) Befor e in st a llin g pist on a n d con n ect in g r od
a ssem blies in t o t h e bor e, in st a ll t h e pist on r in gs.
(2) Im m er se t h e pist on h ea d a n d r in gs in clea n
en gin e oil. P osit ion a r in g com pr essor over t h e pist on
a n d r in gs. Tigh t en r in g com pr essor. En s u re p o s i-
tio n o f rin g s d o n o t c h a n g e d u rin g th is o p e ra -
tio n .
(3) P osit ion bea r in g on t o con n ect in g r od. E n su r e
t h a t h ole in bea r in g sh ell a lign s wit h h ole in con n ect -
in g r od. Lu br ica t e bea r in g su r fa ce wit h clea n en gin e
oil.
Fig. 71 Identify Connecting Rod to Cylinder (4) In st a ll Specia l Tool 8507 Con n ect in g Rod
Position—Typical Gu ides in t o con n ect in g r od bolt t h r ea ds (F ig. 72).
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Im m edia t ely a ft er pist on a n d con n ect in g r od

r em ova l, in st a ll bea r in g ca p on t h e m a t in g con n ect -
in g r od t o pr even t da m a ge t o t h e fr a ct u r ed ca p a n d
r od su r fa ces.
(7) Ca r efu lly r em ove pist on r in gs fr om pist on (s),
st a r t in g fr om t h e t op r in g down .
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usin g a su it a ble clea n in g solven t clea n t h e pis-

t on s in wa r m wa t er a n d t owel dr y.
(2) Use a wood or pla st ic scr a per t o clea n t h e r in g
la n d gr ooves.
CAUTION: DO NOT remove the piston pin from the

piston and connecting rod assembly.
INSPECTION
Ch eck t h e con n ect in g r od jou r n a l for excessive
wea r, t a per a n d scor in g. Refer t o Con n ect in g Rod
Bea r in gs in t h e Ser vice P r ocedu r es por t ion of t h is Fig. 72 Piston and Connecting Rod—Installation
Sect ion . 1 - “F” TOWARD FRONT OF ENGINE
Ch eck t h e con n ect in g r od for sign s of t wist or ben d- 2 - OIL SLINGER SLOT
in g. 3 - RING COMPRESSOR
Ch eck t h e pist on for t a per a n d ellipt ica l sh a pe
befor e it is fit t ed in t o t h e cylin der bor e. Refer t o F it -
t in g P ist on s in t h e Ser vice P r ocedu r es por t ion of t h is (5) Th e pist on s a r e m a r ked on t h e pist on pin bor e
Sect ion . su r fa ce wit h a n r a ised “F ” in dica t in g in st a lla t ion
Ch eck t h e pist on for scor in g, or scr a pin g m a r ks in posit ion . Th is m a r k m u st be poin t in g t owa r d t h e
t h e pist on skir t s. Ch eck t h e r in g la n ds for cr a cks fr on t of en gin e on bot h cylin der ba n ks. Th e con n ect -
a n d/or det er ior a t ion . in g r od oil slin ger slot fa ces t h e fr on t of t h e en gin e
(F ig. 73).
(6) Wipe cylin der bor e clea n a n d lu br ica t e wit h
en gin e oil.
PI ST ON RI N GS
STANDARD PROCEDURE—PISTON RING -
FITTING
Befor e r ein st a llin g u sed r in gs or in st a llin g n ew
r in gs, t h e r in g clea r a n ces m u st be ch ecked.
(1) Wipe t h e cylin der bor e clea n .
(2) In ser t t h e r in g in t h e cylin der bor e.
NOTE: The ring gap measurement must be made

with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Usin g a pist on , t o en su r e t h a t t h e r in g is

squ a r ed in t h e cylin der bor e, slide t h e r in g down wa r d
in t o t h e cylin der.
(4) Usin g a feeler ga u ge ch eck t h e r in g en d ga p
(F ig. 74). Repla ce a n y r in gs n ot wit h in specifica t ion .
Fig. 73 Piston and Connecting Rod Orientation

1 - MAJOR THRUST SIDE OF PISTON
2 - OIL SLINGER SLOT
(7) Rot a t e cr a n ksh a ft u n t il con n ect in g r od jou r n a l

is on t h e cen t er of cylin der bor e. In ser t r od a n d pis-
t on in t o cylin der bor e a n d ca r efu lly posit ion con n ect -
in g r od gu ides over cr a n ksh a ft jou r n a l.
(8) Ta p pist on down in cylin der bor e u sin g a h a m -
m er h a n dle. Wh ile a t t h e sa m e t im e, gu ide con n ect -
in g r od in t o posit ion on r od jou r n a l.
CAUTION: Connecting Rod Bolts are Torque to

Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
Fig. 74 Ring End Gap Measurement - Typical
(9) Lu br ica t e r od bolt s a n d bea r in g su r fa ces wit h 1 - FEELER GAUGE
en gin e oil. In st a ll con n ect in g r od ca p a n d bea r in g.
Tigh t en bolt s t o 27 N·m (20 ft . lbs.) plu s 90°. P IS TON RIN G S ID E CLEARAN CE
(10) In st a ll t h e followin g com pon en t s:
• Cylin der h ea d(s). (Refer t o 9 - E NGINE /CYLIN- NOTE: Make sure the piston ring grooves are clean
DE R H E AD - INSTALLATION). and free of nicks and burrs.
• Tim in g ch a in a n d cover. (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT / CH AIN COVE R(S) (5) Mea su r e t h e r in g side clea r a n ce a s sh own (F ig.
- INSTALLATION). 75)m a ke su r e t h e feeler ga u ge fit s sn u gly bet ween
• Cylin der h ea d cover s (Refer t o 9 - E NGINE / t h e r in g la n d a n d t h e r in g. Repla ce a n y r in g n ot
CYLINDE R H E AD/CYLINDE R H E AD COVE R(S) - wit h in specifica t ion .
INSTALLATION). (6) Rot a t e t h e r in g a r ou n d t h e pist on , t h e r in g
• Oil pa n a n d ga sket /win da ge t r a y. (Refer t o 9 - m u st r ot a t e in t h e gr oove wit h ou t bin din g.
E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) F ill cr a n kca se wit h pr oper en gin e oil t o cor-
r ect level.
(7) Th e No. 1 a n d No. 2 pist on r in gs h a ve a differ-
en t cr oss sect ion . E n su r e No. 2 r in g is in st a lled wit h
m a n u fa ct u r er s I.D. m a r k (Dot ) fa cin g u p, t owa r ds t op
of t h e pist on .
NOTE: Piston rings are installed in the following

order:
• Oil r in g expa n der.

• Upper oil r in g side r a il.
• Lower oil r in g side r a il.
• No. 2 In t er m edia t e pist on r in g.
• No. 1 Upper pist on r in g.
(8) In st a ll t h e oil r in g expa n der.
(9) In st a ll u pper side r a il (F ig. 76) by pla cin g on e
en d bet ween t h e pist on r in g gr oove a n d t h e expa n der
r in g. H old en d fir m ly a n d pr ess down t h e por t ion t o
be in st a lled u n t il side r a il is in posit ion . Repea t t h is
st ep for t h e lower side r a il.
(10) In st a ll No. 2 in t er m edia t e pist on r in g u sin g a
pist on r in g in st a ller (F ig. 77).
(11) In st a ll No. 1 u pper pist on r in g u sin g a pist on
Fig. 75 Measuring Piston Ring Side Clearance r in g in st a ller (F ig. 77).
(12) P osit ion pist on r in g en d ga ps a s sh own in
1 - FEELER GAUGE
(F ig. 78). It is im por t a n t t h a t expa n der r in g ga p is a t
lea st 45° fr om t h e side r a il ga ps, bu t n ot on t h e pis-
PI ST ON RI N G SPECI FI CAT I ON CH ART t on pin cen t er or on t h e t h r u st dir ect ion .
Ring Position Groove Maximum

Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037 (0.004 in.)
in.)
Intermediate 0.04-0.08mm 0.10mm
Ring
(0.0016-0.0031 (0.004 in.)
in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090 (0.010 in.)
in.)
Ring Position Ring Gap Wear Limit Fig. 76 Side Rail—Installation
Upper Ring 0.20-0.36mm 0.40mm 1 - SIDE RAIL END
(0.008-0.014 (0.0016in.)
in.)
Intermediate 0.37-0.63mm 0.71mm
V I BRAT I ON DAM PER
Ring
REMOVAL
(0.014-0.025 (0.028in.) (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
in.) (2) Rem ove a ccessor y dr ive belt (Refer t o 7 -
Oil Control Ring 0.025-0.76mm 1.52mm COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL).
(Steel Rail) (0.010- 0.030 (0.060in.)
in.) NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
Fig. 77 Upper and Intermediate Rings—Installation
Fig. 79 Crankshaft Damper—Removal

1 - SPECIAL TOOL 8513 INSERT
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
Fig. 78 Piston Ring End Gap Position
(1) Align cr a n ksh a ft da m per slot wit h key in
1 - SIDE RAIL UPPER
cr a n ksh a ft . Slide da m per on t o cr a n ksh a ft sligh t ly.
2 - NO. 1 RING GAP
3 - PISTON PIN
CAUTION: Special Tool 8512A, is assembled in a
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(3) Rem ove cr a n ksh a ft da m per bolt .
(4) Rem ove da m per u sin g Specia l Tools 8513
In ser t a n d 1026 Th r ee J a w P u ller (F ig. 79).
(2) Assem ble Specia l Tool 8512–A a s follows, Th e
n u t is t h r ea ded on t o t h e sh a ft fir st . Th en t h e r oller
bea r in g is pla ced on t o t h e t h r ea ded r od (Th e h a r d-
en ed bea r in g su r fa ce of t h e bea r in g MU S T fa ce t h e
n u t ). Th en t h e h a r den ed wa sh er slides on t o t h e
t h r ea ded r od (F ig. 80). On ce a ssem bled coa t t h e
t h r ea ded r od’s t h r ea ds wit h Mopa r ! Nickel An t i-
Seize or (Loct it e No. 771).
Fig. 81 Crankshaft Damper Installation

1 - SPECIAL TOOL 8512A
Fig. 80 Proper Assembly Method for Special Tool

(2) Rem ove t h e left h a n d exh a u st pipe fr om
8512–A
exh a u st m a n ifold.
1 - BEARING
(3) Loosen t h e r igh t h a n d exh a u st m a n ifold-t o-ex-
2 - NUT
h a u st pipe r et a in in g bolt s.
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
(4) Rem ove t h e eigh t bolt s r et a in in g st r u ct u r a l
5 - HARDENED WASHER cover (F ig. 82).
(5) P ivot t h e exh a u st pipe down wa r d a n d r em ove
t h e st r u ct u r a l cover.
(3) Usin g Specia l Tool 8512A, pr ess da m per on t o
cr a n ksh a ft (F ig. 81).
(4) In st a ll t h en t igh t en cr a n ksh a ft da m per bolt t o
175 N·m (130 ft . lbs.).
(5) In st a ll a ccessor y dr ive belt (Refer t o 7 - COOL-
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL-
LATION).
ST RU CT U RAL COV ER
DESCRIPTION
Th e st r u ct u r a l du st cover is m a de of die ca st a lu -
m in u m a n d join s t h e lower h a lf of t h e t r a n sm ission
bell h ou sin g t o t h e en gin e bedpla t e.
OPERATION Fig. 82 Structural Cover

Th e st r u ct u r a l cover pr ovides a ddit ion a l power-
t r a in st iffn ess a n d r edu ces n oise a n d vibr a t ion .
INSTALLATION
CAUTION: The structural cover must be installed as
REMOVAL described in the following steps. Failure to do so
(1) Ra ise veh icle on h oist . will cause severe damage to the cover.
ST RU CT U RAL COV ER (Cont inue d)
(1) P osit ion t h e st r u ct u r a l cover in t h e veh icle.
(2) In st a ll a ll fou r bolt s r et a in in g t h e cover-t o-en -
gin e. DO NOT t igh t en t h e bolt s a t t h is t im e.
(3) In st a ll t h e fou r cover-t o-t r a n sm ission bolt s. Do
NOT t igh t en a t t h is t im e.
CAUTION: The structural cover must be held tightly

against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) St a r t in g wit h t h e t wo r ea r cover-t o-en gin e

bolt s, t igh t en bolt s (1) (F ig. 83) t o 54 N·m (40 ft . lbs.),
t h en t igh t en bolt s (2) (F ig. 83) a n d (3) t o 54 N·m ( 40
ft . lbs.) in t h e sequ en ce sh own .
Fig. 84 Engine Insulator Mount—Left

1 - LOCK NUT ( 1 PER SIDE)
2 - BOLT ( 4 PER SIDE)
(5) Usin g t h e ja ck, r a ise t h e en gin e h igh en ou gh t o

r em ove t h e en gin e in su la t or m ou n t t h r ou gh bolt a n d
t h e in su la t or m ou n t .
INSTALLATION
Fig. 83 Structural Cover
(1) P osit ion t h e in su la t or m ou n t a n d in st a ll t h e
(5) In st a ll t h e exh a u st pipe on left h a n d exh a u st in su la t or m ou n t t h r ou gh bolt .
m a n ifold. (2) Lower t h e en gin e u n t il t h e fou r cylin der block-
(6) Tigh t en exh a u st m a n ifold-t o-exh a u st pipe t o-in su la t or m ou n t bolt s ca n be in st a lled.
r et a in in g bolt s t o 20–26 N·m (15–20 ft . lbs.). (3) Rem ove t h e ja ck a n d block of wood.
(4) Tor qu e t h e cylin der block-t o-in su la t or m ou n t
bolt s t o 61N·m ( 45 ft . lbs.).
FRON T M OU N T (5) In st a ll a n d t or qu e t h e t h r ou gh bolt r et a in in g
n u t t o 61N·m (45 ft . lbs.).
REMOVAL
(1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.
REAR M OU N T
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may REMOVAL
cause damage to the fan blade, fan clutch and fan (1) Ra ise veh icle on h oist .
shroud. (2) Usin g a su it a ble ja ck, su ppor t t r a n sm ission .
(3) Rem ove t h e lock n u t fr om t h e in su la t or m ou n t
(2) Rem ove t h e en gin e oil filt er (Refer t o 9 -
t h r ou gh bolt a n d t h e fou r in su la t or-t o-t r a n sm ission
E NGINE /LUBRICATION/OIL F ILTE R - RE MOVAL).
m ou n t in g bolt s.
(3) Su ppor t t h e en gin e wit h a su it a ble ja ck a n d a
(4) Ra ise t h e t r a n sm ission en ou gh t o r em ove t h e
block of wood a cr oss t h e fu ll widt h of t h e en gin e oil
t h r ou gh bolt a n d in su la t or m ou n t (F ig. 86) (F ig. 87).
pa n .
(4) Rem ove t h e fou r cylin der block-t o-in su la t or
m ou n t bolt s a n d t h e n u t for m t h e en gin e in su la t or
m ou n t t h r ou gh bolt (F ig. 84) (F ig. 85)
REAR M OU N T (Cont inue d)
Fig. 87 Engine Rear Mount—4X4
ITEM DESCRIPTION TORQUE

1 NUT 45 N·m
(Qty 1) (33 ft. lbs)

Fig. 85 Engine Insulator Mount—Right 2 BOLT 46 N·m
1 - LOCK NUT ( 1 PER SIDE)
(Qty 4) (34 ft. lbs.)
2 - BOLT ( 4 PER SIDE)
3 BOLT 68 N·m
(Qty 2 Per (50 ft. lbs.)

Side)
4 BOLT 46 N·m
(Qty 2 Per (34 ft. lbs.)

Side)
5 BOLT 46 N·m
(Qty 4) (34 ft. lbs.)
INSTALLATION
(1) P osit ion t h e in su la t or m ou n t a n d in st a ll t h e
t h r ou gh bolt .
(2) Lower t h e t r a n sm ission en ou gh t o in st a ll t h e
fou r in su la t or-t o-t r a n sm ission m ou n t in g bolt s. Tor qu e
t h e bolt s t o 46 N·m (34 ft . lbs.).
(3) In st a ll t h e t h r ou gh bolt lock n u t . Tor qu e n u t t o
68 N·m (50 ft . lbs.).
(4) Rem ove ja ck, lower veh icle.
Fig. 86 Engine Rear Mount—4X2

LU BRI CAT I ON
DESCRIPTION
Th e lu br ica t ion syst em (F ig. 88) is a fu ll flow fil-
t r a t ion pr essu r e feed t ype.
Fig. 88 Engine Oil Lubrication System

1 - LEFT CYLINDER HEAD OIL GALLERY 7 - TO CRANKSHAFT MAIN JOURNALS
2 - OIL PRESSURE SENSOR LOCATION 8 - RIGHT CYLINDER HEAD OIL GALLERY
3 - TO LEFT CYLINDER HEAD 9 - TO RIGHT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT 10 - CYLINDER BLOCK MAIN GALLERY
5 - OIL PUMP OUTLET TO BLOCK 11 - OIL FEED TO BOTH SECONDARY TENSIONERS
6 - OIL PUMP
OPERATION lobes a r e n ot lu bed in t h e sa m e m a n n er a s t h e

Oil fr om t h e oil pa n is pu m ped by a ger ot or t ype oil exh a u st lobes. Th e in t a ke lobes a r e lu bed t h r ou gh
pu m p dir ect ly m ou n t ed t o t h e cr a n ksh a ft n ose. Oil in t er n a l pa ssa ges in t h e ca m sh a ft . Oil flows t h r ou gh
pr essu r e is con t r olled by a r elief va lve m ou n t ed a bor e in t h e n u m ber 3 ca m sh a ft bea r in g bor e, a n d
in side t h e oil pu m p h ou sin g. F or lu br ica t ion flow a s t h e ca m sh a ft t u r n s, a h ole in t h e ca m sh a ft a lign s
r efer t o (F ig. 88). wit h t h e h ole in t h e ca m sh a ft bor e a llowin g en gin e
Th e ca m sh a ft exh a u st va lve lobes a n d r ocker a r m s oil t o en t er t h e ca m sh a ft t u be. Th e oil t h en exit s
a r e lu br ica t ed t h r ou gh a sm a ll h ole in t h e r ocker t h r ou gh 1.6m m (0.063 in .) h oles dr illed in t o t h e
a r m ; oil flows t h r ou gh t h e la sh a dju st er t h en t h r ou gh in t a ke lobes, lu br ica t in g t h e lobes a n d t h e r ocker
t h e r ocker a r m a n d on t o t h e ca m sh a ft lobe. Du e t o a r m s.
t h e or en t a t ion of t h e r ocker a r m , t h e ca m sh a ft in t a ke
EN GI N E LU BRI CAT I ON FLOW CH ART —BLOCK : TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
1. Crankshaft Main Journal
Block Main Oil Gallery 2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
1. Front Timing Chain Idler Shaft
Crankshaft Number One Main Journal
2. Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head
gaskets have an oil restricter to control oil flow to the cylinder heads.
EN GI N E LU BRI CAT I ON FLOW CH ART —CY LI N DER H EADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to 1. Base of Camshaft Towers
front) 2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
DIAGNOSIS AND TESTING—ENGINE OIL • Cu r b Idle—25 Kpa (4 psi) m in im u m

• 3000 r pm —170 - 550 KP a (25 - 80 psi)
PRESSURE
(4) If oil pr essu r e is 0 a t idle, sh u t off en gin e.
(1) Rem ove oil pr essu r e sen din g u n it (F ig. 89)a n d
Ch eck for a clogged oil pick-u p scr een or a pr essu r e
in st a ll ga u ge a ssem bly C-3292.
r elief va lve st u ck open .
(2) Ru n en gin e u n t il t h er m ost a t open s.
(3) Oil P r essu r e:
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on
t h a t ca n be polish ed ou t wit h em er y clot h .
CAUTION: Use extreme caution when crankshaft

polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft

r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
a ssem bled. (Refer t o 9 - E NGINE - DIAGNOSIS AND
TE STING), u n der t h e Oil Lea k r ow, for com pon en t s
in spect ion s on possible ca u ses a n d cor r ect ion s.
(7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e
cor r ect ive a ct ion h a ve been iden t ified, (Refer t o 9 -
E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
Fig. 89 Oil Pressure Sending Unit SE AL - RE AR - RE MOVAL).
1 - BELT
2 - OIL PRESSURE SENSOR
DIAGNOSIS AND TESTING—ENGINE OIL LEAK
3 - OIL FILTER INSPECTION
4 - ELEC. CONNECTOR Begin wit h a t h or ou gh visu a l in spect ion of t h e
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
DIAGNOSIS AND TESTING—REAR SEAL AREA followin g st eps sh ou ld be followed:
LEAKS (1) Do n ot clea n or degr ea se t h e en gin e a t t h is
Sin ce it is som et im es difficu lt t o det er m in e t h e t im e beca u se som e solven t s m a y ca u se r u bber t o
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e swell, t em por a r ily st oppin g t h e lea k.
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e (2) Add a n oil solu ble dye (u se a s r ecom m en ded by
followin g st eps sh ou ld be followed t o h elp pin poin t m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
t h e sou r ce of t h e lea k. a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
a r ea : wit h a br igh t yellow color u n der a bla ck ligh t .
(1) Discon n ect t h e ba t t er y. (3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
(2) Ra ise t h e veh icle. for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
cover a n d in spect r ea r of block for eviden ce of oil. r epa ir per ser vice m a n u a l in st r u ct ion s.
Use a bla ck ligh t t o ch eck for t h e oil lea k: (4) If dye is n ot obser ved, dr ive t h e veh icle a t va r-
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es iou s speeds for a ppr oxim a t ely 24km (15 m iles), a n d
sea l lea ka ge or cr a n ksh a ft da m a ge. r epea t in spect ion .
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down , (4) If th e o il le a k s o u rc e is n o t p o s itiv e ly
possible ca u ses a r e a por ou s block, dist r ibu t or sea l, id e n tifie d a t th is tim e , pr oceed wit h t h e a ir lea k
ca m sh a ft bor e cu p plu gs, oil ga lley pipe plu gs, oil det ect ion t est m et h od.
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
block m a t in g su r fa ces. See E n gin e, for pr oper Air Leak Detection Test Method
r epa ir pr ocedu r es of t h ese it em s. (1) Discon n ect t h e br ea t h er ca p t o a ir clea n er h ose
(4) If n o lea ks a r e det ect ed, pr essu r ized t h e cr a n k- a t t h e br ea t h er ca p en d. Ca p or plu g br ea t h er ca p
ca se a s ou t lin ed in t h e sect ion , In spect ion (E n gin e oil n ipple.
Lea ks in gen er a l) (2) Rem ove t h e P CV va lve fr om t h e cylin der h ea d
cover. Ca p or plu g t h e P CV va lve gr om m et .
CAUTION: Do not exceed 20.6 kPa (3 psi).
(3) At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d CAUTION: Use extreme caution when crankshaft
r egu la t or t o t h e dipst ick t u be. polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
CAUTION: Do not subject the engine assembly to machined to complement the function of the rear oil
more than 20.6 kpa (3 PSI) of test pressure. seal.
(4) Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5 (6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft

psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s- r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis-
pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble a ssem bled.
t est pr essu r e t h a t pr ovide t h e best bu bbles wh ich
will pin poin t t h e lea k sou r ce. If t h e oil lea k is
det ect ed a n d iden t ified, r epa ir per ser vice m a n u a l OI L
pr ocedu r es.
(5) If t h e lea ka ge occu r s a t t h e r ea r oil sea l a r ea , STANDARD PROCEDURE—ENGINE OIL
r efer t o t h e sect ion , In spect ion for Rea r Sea l Ar ea
Lea k. WARNING: NEW OR USED ENGINE OIL CAN BE
(6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply IRRITATING TO THE SKIN. AVOID PROLONGED OR
a n d r em ove t h e a ir h ose a n d a ll plu gs a n d ca ps. REPEATED SKIN CONTACT WITH ENGINE OIL.
In st a ll t h e P CV va lve a n d br ea t h er ca p h ose. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
(7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
a su it a ble solven t . Dr ive t h e veh icle a t va r iou s YOUR HEALTH. THOROUGHLY WASH EXPOSED
speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e SKIN WITH SOAP AND WATER. DO NOT WASH
en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t . SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
INSPECTION FOR REAR SEAL AREA LEAKS NOT POLLUTE, DISPOSE OF USED ENGINE OIL
Sin ce it is som et im es difficu lt t o det er m in e t h e PROPERLY.
sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
followin g st eps sh ou ld be followed t o h elp pin poin t ENGINE OIL SPECIFICATION
t h e sou r ce of t h e lea k.
If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l CAUTION: Do not use non-detergent or straight
a r ea : mineral oil when adding or changing crankcase
(1) Discon n ect t h e ba t t er y. lubricant. Engine failure can result.
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g
API SERVICE GRADE CERTIFIED
cover a n d in spect r ea r of block for eviden ce of oil.
Use a n en gin e oil t h a t is AP I Ser vice Gr a de Cer t i-
Use a bla ck ligh t t o ch eck for t h e oil lea k:
fied. MOPAR! pr ovides en gin e oils t h a t con for m t o
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es
t h is ser vice gr a de.
sea l lea ka ge or cr a n ksh a ft da m a ge.
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down ,
SAE VISCOSITY
possible ca u ses a r e a por ou s block, dist r ibu t or sea l,
An SAE viscosit y gr a de is u sed t o specify t h e vis-
ca m sh a ft bor e cu p plu gs oil ga lley pipe plu gs, oil
cosit y of en gin e oil. Use on ly en gin e oils wit h m u lt i-
filt er r u n off, a n d m a in bea r in g ca p t o cylin der
ple viscosit ies su ch a s 5W-30 or 10W-30 in t h e 4.7L
block m a t in g su r fa ces.
en gin es. Th ese a r e specified wit h a du a l SAE viscos-
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k-
it y gr a de wh ich in dica t es t h e cold-t o-h ot t em per a t u r e
ca se a s ou t lin ed in t h e, In spect ion (E n gin e oil Lea ks
viscosit y r a n ge. Select a n en gin e oil t h a t is best
in gen er a l)
su it ed t o you r pa r t icu la r t em per a t u r e r a n ge a n d va r i-
CAUTION: Do not exceed 20.6 kPa (3 psi). a t ion (F ig. 90).
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e ENERGY CONSERVING OIL
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is An E n er gy Con ser vin g t ype oil is r ecom m en ded for
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile ga solin e en gin es. Th e design a t ion of E NE RGY CON-
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e SE RVING is loca t ed on t h e la bel of a n en gin e oil con -
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on t a in er.
t h a t ca n be polish ed ou t wit h em er y clot h .
OI L (Cont inue d)
Fig. 90 Temperature/Engine Oil Viscosity—4.7L

Engine
CONTAINER IDENTIFICATION
St a n da r d en gin e oil iden t ifica t ion n ot a t ion s h a ve
been a dopt ed t o a id in t h e pr oper select ion of en gin e
oil. Th e iden t ifyin g n ot a t ion s a r e loca t ed on t h e la bel
of en gin e oil pla st ic bot t les a n d t h e t op of en gin e oil
ca n s (F ig. 91).
Fig. 92 Engine Oil Dipstick 4.7L Engine
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
3 - ENGINE OIL FILL CAP
(4) In st a ll dipst ick a n d ver ify it is sea t ed in t h e

t u be.
(5) Rem ove dipst ick, wit h h a n dle h eld a bove t h e
t ip, t a ke oil level r ea din g.
Fig. 91 Engine Oil Container Standard Notations (6) Add oil if level is below t h e SAF E ZONE on
dipst ick.
OIL LEVEL INDICATOR (DIPSTICK)
Th e en gin e oil level in dica t or is loca t ed on t h e ENGINE OIL CHANGE
r igh t side of t h e t h e 4.7L en gin e. (F ig. 92). Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls
descr ibed in Ma in t en a n ce Sch edu les.
CRANKCASE OIL LEVEL INSPECTION Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em -
per a t u r e.
CAUTION: Do not overfill crankcase with engine oil, (1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n
pressure loss or oil foaming can result. en gin e off.
(2) Rem ove oil fill ca p.
In spect en gin e oil level a ppr oxim a t ely ever y 800
(3) H oist a n d su ppor t veh icle on sa fet y st a n ds.
kilom et er s (500 m iles). Un less t h e en gin e h a s exh ib-
(4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
it ed loss of oil pr essu r e, r u n t h e en gin e for a bou t five
dr a in .
m in u t es befor e ch eckin g oil level. Ch eckin g en gin e oil
(5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow
level on a cold en gin e is n ot a ccu r a t e.
oil t o dr a in in t o pa n . In spect dr a in plu g t h r ea ds for
To en su r e pr oper lu br ica t ion of a n en gin e, t h e
st r et ch in g or ot h er da m a ge. Repla ce dr a in plu g if
en gin e oil m u st be m a in t a in ed a t a n a ccept a ble level.
da m a ged.
Th e a ccept a ble levels a r e in dica t ed bet ween t h e ADD
(6) In st a ll dr a in plu g in cr a n kca se.
a n d SAF E m a r ks on t h e en gin e oil dipst ick.
(7) Rem ove oil filt er (Refer t o 9 - E NGINE /LUBRI-
(1) P osit ion veh icle on level su r fa ce.
CATION/OIL F ILTE R - RE MOVAL).
(2) Wit h en gin e OF F, a llow a ppr oxim a t ely t en m in -
(8) Lower veh icle a n d fill cr a n kca se wit h specified
u t es for oil t o set t le t o bot t om of cr a n kca se, r em ove
t ype a n d a m ou n t of en gin e oil descr ibed in t h is sec-
en gin e oil dipst ick.
t ion .
(3) Wipe dipst ick clea n .
(9) In st a ll oil fill ca p.
OI L (Cont inue d)
(10) St a r t en gin e a n d in spect for lea ks. INSTALLATION
(11) St op en gin e a n d in spect oil level. (1) Ligh t ly lu br ica t e oil filt er ga sket wit h en gin e
oil.
USED ENGINE OIL DISPOSAL (2) Th r ea d filt er on t o a da pt er n ipple. Wh en ga sket
Ca r e sh ou ld be exer cised wh en disposin g u sed m a kes con t a ct wit h sea lin g su r fa ce, (F ig. 94)h a n d
en gin e oil a ft er it h a s been dr a in ed fr om a veh icle t igh t en filt er on e fu ll t u r n , do n ot over t igh t en .
en gin e. Refer t o t h e WARNING a t begin n in g of t h is (3) Add oil, ver ify cr a n kca se oil level a n d st a r t
sect ion . en gin e. In spect for oil lea ks.
OI L FI LT ER
REMOVAL
All en gin es a r e equ ipped wit h a h igh qu a lit y fu ll-
flow, disposa ble t ype oil filt er. Da im ler Ch r ysler Cor-
por a t ion r ecom m en ds a Mopa r ! or equ iva len t oil
filt er be u sed.
(1) P osit ion a dr a in pa n u n der t h e oil filt er.
(2) Usin g a su it a ble oil filt er wr en ch loosen filt er.
(3) Rot a t e t h e oil filt er cou n t er clockwise (F ig. 93)t o
r em ove it fr om t h e cylin der block oil filt er boss.
Fig. 94 Oil Filter Sealing Surface—Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
OI L PAN
DESCRIPTION
Th e en gin e oil pa n is m a de of la m in a t ed st eel a n d
h a s a sin gle pla n e sea lin g su r fa ce. Th e sa n dwich
st yle oil pa n ga sket h a s a n in t egr a t ed win da ge t r a y
a n d st eel ca r r ier. Th e sea lin g a r ea of t h e ga sket is
m olded wit h r u bber a n d is design ed t o be r eu sed a s
lon g a s t h e ga sket is n ot cu t , t or n or r ipped.
REMOVAL
(2) Ra ise veh icle on h oist .
(3) Rem ove st r u ct u r a l cover (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - RE MOV-
Fig. 93 Oil Filter - 4.7L Engine AL).
1 - ENGINE OIL FILTER (4) Rem ove exh a u st syst em Y-pipe.
(5) Rem ove st a r t er (Refer t o 8 - E LE CTRICAL/
STARTING/STARTE R MOTOR - RE MOVAL).
(4) Wh en filt er sepa r a t es fr om cylin der block oil
(6) Dr a in en gin e oil.
filt er boss, t ip ga sket en d u pwa r d t o m in im ize oil
(7) Un -clip t r a n sm ission lin es fr om su ppor t on oil
spill. Rem ove filt er fr om veh icle.
pa n st u d. Move lin es for oil pa n clea r a n ce.
NOTE: Make sure filter gasket was removed with fil-
CAUTION: DO NOT pry on the oil pan gasket when
ter.
removing the oil pan, The oil pan gasket is mounted
(5) Wit h a wipin g clot h , clea n t h e ga sket sea lin g to the cylinder block in three locations and will
su r fa ce of oil a n d gr im e. remain attached to block when lowering oil pan.
Gasket can not be removed with oil pan.
(8) Rem ove oil pa n bolt s a n d oil pa n . (8) In st a ll st r u ct u r a l cover (Refer t o 9 - E NGINE /
(9) Rem ove oil pu m p picku p t u be. E NGINE BLOCK/STRUCTURAL COVE R - INSTAL-
(10) Rem ove oil pa n ga sket . LATION).
(9) Lower veh icle.
CLEANING (10) F ill en gin e wit h pr oper a m ou n t of oil (Refer t o
(1) Clea n oil pa n in solven t a n d wipe dr y wit h a LUBRICATION & MAINTE NANCE /F LUID TYP E S -
clea n clot h . SP E CIF ICATIONS).
(2) Clea n t h e oil pa n ga sket su r fa ce. D O N OT u se (11) Con n ect n ega t ive ca ble t o ba t t er y.
a gr in der wh eel or ot h er a br a sive t ool t o clea n sea l-
in g su r fa ce.
(3) Clea n oil scr een a n d t u be t h or ou gh ly in clea n OI L PRESSU RE SEN SOR/
solven t . SWI T CH
INSPECTION DESCRIPTION
(1) In spect oil dr a in plu g a n d plu g h ole for Th e 3–wir e, solid-st a t e en gin e oil pr essu r e sen sor
st r ipped or da m a ged t h r ea ds. Repa ir a s n ecessa r y. (sen din g u n it ) is loca t ed in a n en gin e oil pr essu r e
(2) In spect t h e oil pa n m ou n t in g fla n ge for ben ds ga ller y.
or dist or t ion . St r a igh t en fla n ge, if n ecessa r y.
OPERATION
INSTALLATION Th e oil pr essu r e sen sor u ses t h r ee cir cu it s. Th ey
(1) Clea n oil pa n a n d a ll sea lin g su r fa ces. In spect a r e:
oil pa n ga sket a n d r epla ce a s n ecessa r y. • A 5–volt power su pply fr om t h e P ower t r a in Con -
(2) In st a ll oil pa n ga sket . t r ol Modu le (P CM)
• A sen sor gr ou n d t h r ou gh t h e P CM’s sen sor
NOTE: When installing oil pan gasket/windage tray, r et u r n
start four pan bolts at each corner before tightening • A sign a l t o t h e P CM r ela t in g t o en gin e oil pr es-
oil pickup tube. This will keep pan gasket in align- su r e
ment. Th e oil pr essu r e sen sor h a s a 3–wir e elect r ica l
fu n ct ion ver y m u ch like t h e Ma n ifold Absolu t e P r es-
(3) In st a ll oil pu m p pick-u p t u be u sin g a n ew
su r e (MAP ) sen sor. Mea n in g differ en t pr essu r es
O-r in g. F ir st t igh t en bolt a t O-r in g en d of t u be t o 28
r ela t e t o differ en t ou t pu t volt a ges.
N·m (20 ft . lbs.). Tigh t en r em a in t u be su ppor t fa st en -
A 5–volt su pply is sen t t o t h e sen sor fr om t h e P CM
er s t o 28 N·m (20 ft . lbs.).
t o power u p t h e sen sor. Th e sen sor r et u r n s a volt a ge
(4) In st a ll oil pa n a n d t igh t en fa st en er s t o 15 N·m
sign a l ba ck t o t h e P CM r ela t in g t o en gin e oil pr es-
(11 ft . lbs.) (F ig. 95).
su r e. Th is sign a l is t h en t r a n sfer r ed (bu ssed) t o t h e
in st r u m en t pa n el on eit h er a CCD or P CI bu s cir cu it
(depen din g on veh icle lin e) t o oper a t e t h e oil pr essu r e
ga u ge a n d t h e ch eck ga u ges la m p. Gr ou n d for t h e
sen sor is pr ovided by t h e P CM t h r ou gh a low-n oise
sen sor r et u r n .
REMOVAL
(1) Discon n ect t h e n ega t ive ca ble fr om t h e ba t t er y.
(2) Ra ise veh icle on h oist .
(3) Rem ove fr on t spla sh sh ield.
(4) Discon n ect oil pr essu r e sen der wir e (F ig. 96).
Fig. 95 Oil Pan Tightening Sequence

(5) Recon n ect t r a n sm ission oil cooler lin es t o oil
pa n st u d bolt .
(6) In st a ll st a r t er (Refer t o 8 - E LE CTRICAL/
STARTING/STARTE R MOTOR - INSTALLATION).
(7) In st a ll exh a u st syst em Y-pipe.
OI L PRESSU RE SEN SOR/SWI T CH (Cont inue d)
(5) Rem ove t h e pr essu r e sen der (F ig. 96). NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) If it is n ecessa r y t o r em ove t h e pr essu r e r elief

va lve, dr ive t h e r oll pin fr om pu m p h ou sin g a n d
r em ove cu p plu g, spr in g a n d va lve.
CLEANING
(1) Wa sh a ll pa r t s in a su it a ble solven t .
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
the these components are disassembled andør
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Clea n a ll pa r t s t h or ou gh ly. Ma t in g su r fa ce of

t h e oil pu m p h ou sin g sh ou ld be sm oot h . If t h e pu m p
cover is scr a t ch ed or gr ooved t h e oil pu m p a ssem bly
sh ou ld be r epla ced.
(2) La y a st r a igh t edge a cr oss t h e pu m p cover su r-
Fig. 96 Oil Pressure Sending Unit fa ce (F ig. 97). If a 0.025 m m (0.001 in .) feeler ga u ge
1 - BELT ca n be in ser t ed bet ween t h e cover a n d t h e st r a igh t
2 - OIL PRESSURE SENSOR edge t h e oil pu m p a ssem bly sh ou ld be r epla ced.
3 - OIL FILTER
(3) Mea su r e t h e t h ickn ess of t h e ou t er r ot or (F ig.
4 - ELEC. CONNECTOR
98). If t h e ou t er r ot or t h ickn ess m ea su r es a t 11.9888
m m (0.472 in .) or less t h e oil pu m p a ssem bly m u st be
INSTALLATION r epla ced.
(1) In st a ll oil pr essu r e sen der. (4) Mea su r e t h e dia m et er of t h e ou t er r ot or. If t h e
(2) Con n ect oil pr essu r e sen der wir e. ou t er r ot or dia m et er m ea su r es a t 85.928 m m (3.382
(3) In st a ll fr on t spla sh sh ield. in .) or less t h e oil pu m p a ssem bly m u st be r epla ced.
(4) Lower veh icle. (5) Mea su r e t h e t h ickn ess of t h e in n er r ot or (F ig.
(5) Con n ect t h e n ega t ive ba t t er y ca ble. 99). If t h e in n er r ot or t h ickn ess m ea su r es a t 11.9888
m m (0.472 in .) or less t h en t h e oil pu m p a ssem bly
OI L PU M P (6) Slide ou t er r ot or in t o t h e body of t h e oil pu m p.
P r ess t h e ou t er r ot or t o on e side of t h e oil pu m p body
REMOVAL a n d m ea su r e clea r a n ce bet ween t h e ou t er r ot or a n d
(1) Rem ove t h e oil pa n a n d pick-u p t u be (Refer t o t h e body (F ig. 100). If t h e m ea su r em en t is 0.235m m
9 - E NGINE /LUBRICATION/OIL PAN - RE MOVAL). (0.009 in .) or m or e t h e oil pu m p a ssem bly m u st be
(2) Rem ove t h e t im in g ch a in cover (Refer t o 9 - r epla ced.
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN (7) In st a ll t h e in n er r ot or in t h e in t o t h e oil pu m p
COVE R(S) - RE MOVAL). body. Mea su r e t h e clea r a n ce bet ween t h e in n er a n d
(3) Rem ove t h e t im in g ch a in s a n d t en sion er s ou t er r ot or s (F ig. 101). If t h e clea r a n ce bet ween t h e
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING r ot or s is .150 m m (0.006 in .) or m or e t h e oil pu m p
BE LT/CH AIN AND SP ROCKE TS - RE MOVAL). a ssem bly m u st be r epla ced.
(4) Rem ove t h e fou r bolt s, pr im a r y t im in g ch a in (8) P la ce a st r a igh t edge a cr oss t h e body of t h e oil
t en sion er a n d t h e oil pu m p. pu m p (bet ween t h e bolt h oles), if a feeler ga u ge of
.095 m m (0.0038 in .) or gr ea t er ca n be in ser t ed
DISASSEMBLE bet ween t h e st r a igh t edge a n d t h e r ot or s, t h e pu m p
m u st be r epla ced (F ig. 102).
(1) Rem ove oil pu m p cover scr ews a n d lift off cover
pla t e.
(2) Rem ove pu m p in n er a n d ou t er r ot or s.
NOTE: 4.7 Oil pump is released as an assembly.
There are no DaimlerChrysler part numbers for Sub-
Assembly components. In the event the oil pump is
not functioning or out of specification it must be
replaced as an assembly.
Fig. 99 Measuring Inner Rotor Thickness
Fig. 97 Checking Oil Pump Cover Flatness

1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 100 Measuring Outer Rotor Clearance in

1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 98 Measuring Outer Rotor Thickness

(5) If oil pr essu r e is low a n d pu m p is wit h in spec-
ifica t ion s, in spect for wor n en gin e bea r in gs or ot h er
ca u ses for oil pr essu r e loss.
INSTALLATION
(1) P osit ion t h e oil pu m p on t o t h e cr a n ksh a ft a n d
in st a ll t wo oil pu m p r et a in in g bolt s.
(2) P osit ion t h e pr im a r y t im in g ch a in t en sion er
a n d in st a ll t h e t wo r et a in in g bolt s.
(3) Tigh t en t h e oil pu m p a n d pr im a r y t im in g ch a in
t en sion er r et a in in g bolt s t o 28 N·m (250 in . lbs.) in
t h e sequ en ce sh own (F ig. 103).
Fig. 101 Measuring Clearance Between Rotors

1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 103 Oil Pump and Primary Timing Chain

Tightening Sequence
(4) In st a ll t h e secon da r y t im in g ch a in t en sion er s
a n d t im in g ch a in s (Refer t o 9 - E NGINE /VALVE
TIMING/TIMING BE LT/CH AIN AND SP ROCKE TS -
INSTALLATION).
Fig. 102 Measuring Clearance Over Rotors (5) In st a ll t h e t im in g ch a in cover (Refer t o 9 -
1 - STRAIGHT EDGE E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
2 - FEELER GAUGE COVE R(S) - INSTALLATION).
(6) In st a ll t h e pick-u p t u be a n d oil pa n (Refer t o 9
- E NGINE /LUBRICATION/OIL PAN - INSTALLA-
TION).
ASSEMBLE
(1) Wa sh a ll pa r t s in a su it a ble solven t a n d in spect I N TAK E M AN I FOLD
ca r efu lly for da m a ge or wea r.
(2) In st a ll in n er a n d ou t er r ot or s DESCRIPTION
(3) In st a ll oil pu m p cover pla t e a n d in st a ll cover Th e in t a ke m a n ifold is m a de of a com posit e m a t e-
bolt s a n d t igh t en t h em t o 12 N·m (105 in . lbs.). r ia l a n d fea t u r es lon g r u n n er s wh ich m a xim izes low
(4) P r im e oil pu m p befor e in st a lla t ion by fillin g en d t or qu e. Th e in t a ke m a n ifold u ses sin gle pla n e
r ot or ca vit y wit h en gin e oil. sea lin g wh ich con sist of eigh t in dividu a l pr ess in
pla ce por t ga sket s t o pr even t lea ks. E igh t st u ds a n d (5) Discon n ect va por pu r ge h ose, br a ke boost er
t wo bolt s a r e u sed t o fa st en t h e in t a ke t o t h e h ea d. h ose, speed con t r ol ser vo h ose, posit ive cr a n kca se
ven t ila t ion (P CV) h ose.
DIAGNOSIS AND TESTING—INTAKE (6) Rem ove a ccessor y dr ive belt (Refer t o 7 -
MANIFOLD LEAKAGE COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by RE MOVAL).
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or (7) Discon n ect gen er a t or elect r ica l con n ect ion s.
m or e cylin der s m a y n ot be fu n ct ion in g. (8) Un bolt t h e gen er a t or a n d m ove it a wa y fr om
t h e in t a ke m a n ifold for clea r a n ce.
WARNING: USE EXTREME CAUTION WHEN THE (9) Discon n ect a ir con dit ion in g com pr essor elect r i-
ENGINE IS OPERATING. DO NOT STAND IN A ca l con n ect ion s.
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR (10) Un bolt t h e a ir con dit ion in g com pr essor a n d
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. m ove it a wa y fr om t h e in t a ke m a n ifold for clea r a n ce.
DO NOT WEAR LOOSE CLOTHING. (11) Discon n ect left a n d r igh t r a dio su ppr essor
st r a ps.
(1) St a r t t h e en gin e. (12) Discon n ect a n d r em ove ign it ion coil t ower s
(2) Spr a y a sm a ll st r ea m of wa t er a t t h e su spect ed (Refer t o 8 - E LE CTRICAL/IGNITION CONTROL/
lea k a r ea . IGNITION COIL - RE MOVAL).
(3) If a ch a n ge in RP M is obser ved t h e a r ea of t h e (13) Rem ove t op oil dipst ick t u be r et a in in g bolt
su spect ed lea k h a s been fou n d. a n d gr ou n d st r a p.
(4) Repa ir a s r equ ir ed. (14) Bleed pr essu r e fr om fu el syst em (Refer t o 14 -
F UE L SYSTE M/F UE L DE LIVE RY - STANDARD
REMOVAL P ROCE DURE ).
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. (15) Rem ove fu el r a il (Refer t o 14 - F UE L SYS-
(2) Rem ove a ir clea n er h ou sin g a n d t h r ot t le body TE M/F UE L DE LIVE RY/F UE L RAIL - RE MOVAL).
r eson a t or (F ig. 104). (16) Rem ove t h r ot t le body a ssem bly a n d m ou n t in g
br a cket .
(17) Dr a in coolin g syst em below coola n t t em per a -
t u r e level (Refer t o 7 - COOLING - STANDARD
P ROCE DURE ).
(18) Rem ove coola n t t em per a t u r e sen sor (Refer t o
7 - COOLING/E NGINE /E NGINE COOLANT TE MP
SE NSOR - RE MOVAL).
(19) Rem ove cowl t o h ood sea l. (Refer t o 23 -
BODY/WE ATH E RSTRIP /SE ALS/COWL WE ATH E R-
STRIP - RE MOVAL).
(20) Rem ove r igh t side en gin e lift in g st u d.
(21) Rem ove in t a ke m a n ifold r et a in in g fa st en er s,
in
(21) r ever se or der of t igh t en in g sequ en ce (F ig.
105).
NOTE: Intake must be lifted upward and level in the

Fig. 104 Throttle Body Resonator
front and rear to clear the cowl. Interference with
1 - THROTTLE BODY RESONATOR the cowl will occur during removal.
2 - BOLT
3 - BOLT (22) Rem ove in t a ke m a n ifold.
(3) Discon n ect t h r ot t le a n d speed con t r ol ca bles. CLEANING

(4) Discon n ect elect r ica l con n ect or s for t h e follow-
in g com pon en t s: NOTE: There is NO approved repair procedure for
• Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor the intake manifold. If severe damage is found dur-
• In t a ke Air Tem per a t u r e (IAT) Sen sor ing inspection, the intake manifold must be
• Th r ot t le P osit ion (TP S) Sen sor replaced.
• Coola n t Tem per a t u r e (CTS) Sen sor
Fig. 105 Intake Manifold Tightening Sequence Fig. 106 Intake Manifold Tightening Sequence
Befor e in st a llin g t h e in t a ke m a n ifold t h or ou gh ly • Coola n t Tem per a t u r e (CTS) Sen sor
clea n t h e m a t in g su r fa ces. Use a su it a ble clea n in g • Idle Air Con t r ol (IAC) Mot or
solven t , t h en a ir dr y. • Ign it ion coil t ower s
• F u el in ject or s
INSPECTION (12) In st a ll t op oil dipst ick t u be r et a in in g bolt a n d
(1) In spect t h e in t a ke sea lin g su r fa ce for cr a cks, gr ou n d st r a p.
n icks a n d dist or t ion . (13) In st a ll r igh t side en gin e lift in g st u d.
(2) In spect t h e in t a ke m a n ifold va cu u m h ose fit - (14) In st a ll gen er a t or in clu din g elect r ica l con n ec-
t in gs for loosen ess or blocka ge. t ion s (Refer t o 8 - E LE CTRICAL/CH ARGING/GE N-
(3) In spect t h e m a n ifold t o t h r ot t le body m a t in g E RATOR - INSTALLATION).
su r fa ce for cr a cks, n icks a n d dist or t ion . (15) Con n ect Va por pu r ge h ose, Br a ke boost er
h ose, Speed con t r ol ser vo h ose, P osit ive cr a n kca se
INSTALLATION ven t ila t ion (P CV) h ose.
(1) In st a ll in t a ke m a n ifold ga sket s. (16) In st a ll a ir con dit ion in g com pr essor in clu din g
(2) In st a ll in t a ke m a n ifold. elect r ica l con n ect ion s.
(3) In st a ll in t a ke m a n ifold r et a in in g bolt s a n d (17) F ill coolin g syst em (Refer t o 7 - COOLING -
t igh t en in sequ en ce sh own in (F ig. 106) t o 12 N·m STANDARD P ROCE DURE ).
(105 in . lbs.). (18) In st a ll a ccessor y dr ive belt (Refer t o 7 -
(4) In st a ll left a n d r igh t r a dio su ppr essor st r a ps. COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
(5) In st a ll t h r ot t le body a ssem bly. INSTALLATION).
(6) In st a ll t h r ot t le ca ble br a cket . (19) In st a ll cowl t o h ood sea l (Refer t o 23 - BODY/
(7) Con n ect t h r ot t le ca ble a n d speed con t r ol ca ble WE ATH E RSTRIP /SE ALS/COWL WE ATH E RSTRIP -
t o t h r ot t le body. INSTALLATION).
(8) In st a ll fu el r a il (Refer t o 14 - F UE L SYSTE M/ (20) In st a ll a ir clea n er h ou sin g a n d t h r ot t le body
F UE L DE LIVE RY/F UE L RAIL - INSTALLATION). r eson a t or. Tigh t en r eson a t or bolt s 4.5 N·m (40 in .
(9) In st a ll ign it ion coil t ower s (Refer t o 8 - E LE C- lbs.).
TRICAL/IGNITION CONTROL/IGNITION COIL - (21) Con n ect n ega t ive ca ble t o ba t t er y.
INSTALLATION).
(10) In st a ll coola n t t em per a t u r e sen sor (Refer t o 7
- COOLING/E NGINE /E NGINE COOLANT TE MP EX H AU ST M AN I FOLD - LEFT
SE NSOR - INSTALLATION).
(11) Con n ect elect r ica l con n ect or s for t h e followin g DESCRIPTION
com pon en t s: Th e exh a u st m a n ifolds a r e log st yle wit h a pa t -
• Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor en t ed flow en h a n cin g design t o m a xim ize per for-
• In t a ke Air Tem per a t u r e (IAT) Sen sor m a n ce. Th e exh a u st m a n ifolds a r e m a de of h igh
• Th r ot t le P osit ion (TP S) Sen sor silicon m olybden u m ca st ir on . A per for a t ed cor e
EX H AU ST M AN I FOLD - LEFT (Cont inue d)
gr a ph it e exh a u st m a n ifold ga sket is u sed t o im pr ove (4) In st a ll exh a u st m a n ifold h ea t sh ield (F ig. 107).
sea lin g t o t h e cylin der h ea d. Th e exh a u st m a n ifolds Tigh t en fa st en er s t o 8 N·m (72 in . lbs.), t h en loosen
a r e cover ed by a t h r ee la yer la m in a t ed h ea t sh ield 45 degr ees.
for t h er m a l pr ot ect ion a n d n oise r edu ct ion . Th e h ea t (5) In st a ll a ir clea n er h ou sin g a n d t u be.
sh ields a r e fa st en ed wit h a t or qu e pr eva ilin g n u t (6) Con n ect exh a u st pipe t o m a n ifold.
t h a t is ba cked off sligh t ly t o a llow for t h e t h er m a l (7) Con n ect n ega t ive ca ble t o ba t t er y.
expa n sion of t h e exh a u st m a n ifold.
REMOVAL EX H AU ST M AN I FOLD - RI GH T
(1) Discon n ect n ega t ive ca ble for ba t t er y.
(2) H oist veh icle. DESCRIPTION
(3) Discon n ect exh a u st pipe a t m a n ifold. Th e exh a u st m a n ifolds a r e log st yle wit h a pa t -
(4) Lower veh icle. en t ed flow en h a n cin g design t o m a xim ize per for-
(5) Rem ove a ir clea n er h ou sin g a n d t u be. m a n ce. Th e exh a u st m a n ifolds a r e m a de of h igh
(6) Rem ove t h e fr on t t wo exh a u st h ea t sh ield silicon m olybden u m ca st ir on . A per for a t ed cor e
r et a in in g fa st en er s. Ra ise veh icle a n d r em ove t h e gr a ph it e exh a u st m a n ifold ga sket is u sed t o im pr ove
fa st en er s a t r ea r of h ea t sh ield. sea lin g t o t h e cylin der h ea d. Th e exh a u st m a n ifolds
(7) Rem ove h ea t sh ield (F ig. 107). a r e cover ed by a t h r ee la yer la m in a t ed h ea t sh ield
(8) Lower veh icle a n d r em ove t h e u pper exh a u st for t h er m a l pr ot ect ion a n d n oise r edu ct ion . Th e h ea t
m a n ifold r et a in in g bolt s (F ig. 107). sh ields a r e fa st en ed wit h a t or qu e pr eva ilin g n u t
(9) Ra ise veh icle a n d r em ove t h e lower exh a u st t h a t is ba cked off sligh t ly t o a llow for t h e t h er m a l
m a n ifold r et a in in g bolt s (F ig. 107). expa n sion of t h e exh a u st m a n ifold.
(10) Rem ove exh a u st m a n ifold a n d ga sket (F ig.
107). Ma n ifold is r em oved fr om below t h e en gin e REMOVAL
com pa r t m en t . (1) Discon n ect n ega t ive ca ble for ba t t er y.
(2) Rem ove ba t t er y fr om veh icle.
CLEANING (3) Rem ove P ower Dist r ibu t ion Cen t er (P DC) fa s-
(1) Clea n t h e exh a u st m a n ifold u sin g a su it a ble t en er s a n d set a side.
clea n in g solven t , t h en a llow t o a ir dr y. (4) Rem ove ba t t er y t r a y a ssem bly.
(2) Clea n a ll ga sket r esidu e fr om t h e m a n ifold (5) Rem ove wa sh er bot t le a ssem bly
m a t in g su r fa ce. (6) Rem ove a ccessor y dr ive belt (Refer t o 7 -
INSPECTION RE MOVAL).
(1) In spect t h e exh a u st m a n ifold for cr a cks in t h e (7) Rem ove A/C com pr essor fr om m ou n t in g a n d set
m a t in g su r fa ce a n d a t ever y m ou n t in g bolt h ole. a side.
(2) Usin g a st r a igh t edge a n d a feeler ga u ge, ch eck (8) Rem ove A/C a ccu m u la t or su ppor t br a cket fa s-
t h e m a t in g su r fa ce for wa r p a n d t wist . t en er.
(3) In spect t h e m a n ifold t o exh a u st pipe m a t in g (9) Dr a in coola n t (Refer t o 7 - COOLING - STAN-
su r fa ce for cr a cks, gou ges, or ot h er da m a ge t h a t DARD P ROCE DURE ).
wou ld pr even t sea lin g. (10) Rem ove h ea t er h oses a t en gin e.
(11) Rem ove fa st en er s a t t a ch in g exh a u st m a n ifold
INSTALLATION h ea t sh ield (F ig. 108).
(1) In st a ll exh a u st m a n ifold a n d ga sket fr om below (12) Rem ove h ea t sh ield (F ig. 108).
en gin e com pa r t m en t . (13) Rem ove u pper exh a u st m a n ifold a t t a ch in g fa s-
(2) In st a ll lower exh a u st m a n ifold fa st en er s (F ig. t en er s (F ig. 108).
107). DO NOT t igh t en u n t il a ll fa st en er s a r e in (14) Ra ise veh icle on h oist .
pla ce. (15) Discon n ect exh a u st pipe fr om m a n ifold.
(3) Lower veh icle a n d in st a ll u pper exh a u st m a n i- (16) Rem ove fa st en er s a t t a ch in g st a r t er. Move
fold fa st en er s (F ig. 107). Tigh t en a ll m a n ifold bolt s st a r t er a side.
st a r t in g a t cen t er a n d wor kin g ou t wa r d t o 25 N·m (17) Rem ove lower exh a u st m a n ifold a t t a ch in g fa s-
(18 ft . lbs.). t en er s.
(18) Rem ove exh a u st m a n ifold a n d ga sket (F ig.
CAUTION: Over tightening heat shield fasteners, 108). Ma n ifold is r em oved fr om below t h e en gin e
may cause shield to distort and/or crack. com pa r t m en t .
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
Fig. 107 Exhaust Manifold—Left

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m (72 in. lbs.),
then loosen 45
2 Bolt (Qty 4) 25 N·m (18 ft. lbs.) 5 Nut (Qty 2) degrees
3 Stud (Qty 2)
CLEANING (3) In spect t h e m a n ifold t o exh a u st pipe m a t in g

su r fa ce for cr a cks, gou ges, or ot h er da m a ge t h a t
(1) Clea n t h e exh a u st m a n ifold u sin g a su it a ble
wou ld pr even t sea lin g.
clea n in g solven t , t h en a llow t o a ir dr y.
(2) Clea n a ll ga sket r esidu e fr om t h e m a n ifold
m a t in g su r fa ce.
INSTALLATION
(1) In st a ll exh a u st m a n ifold a n d ga sket fr om below
INSPECTION en gin e com pa r t m en t .
(2) In st a ll lower exh a u st m a n ifold fa st en er s. DO
(1) In spect t h e exh a u st m a n ifold for cr a cks in t h e
NOT t igh t en u n t il a ll fa st en er s a r e in pla ce.
m a t in g su r fa ce a n d a t ever y m ou n t in g bolt h ole.
(3) Lower veh icle a n d in st a ll u pper exh a u st m a n i-
(2) Usin g a st r a igh t edge a n d a feeler ga u ge, ch eck
fold fa st en er s. Tigh t en a ll m a n ifold bolt s st a r t in g a t
t h e m a t in g su r fa ce for wa r p a n d t wist .
cen t er a n d wor kin g ou t wa r d t o 25 N·m (18 ft . lbs.).
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
Fig. 108 Exhaust Manifold—Right

ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2) 4 Nut (Qty 2) 8 N·m (72 in. lbs.),
then loosen 45
2 Bolt (Qty 4) 25 N·m (18 ft. lbs.) 5 Nut (Qty 2) degrees
3 Stud (Qty 2)
CAUTION: Over tightening heat shield fasteners, (11) In st a ll wa sh er bot t le a n d ba t t er y t r a y a ssem -

may cause shield to distort and/or crack. bly.
(12) In st a ll P DC.
(4) In st a ll exh a u st m a n ifold h ea t sh ield. Tigh t en (13) In st a ll ba t t er y a n d con n ect ca bles.
fa st en er s t o 8 N·m (72 in . lbs.), t h en loosen 45 (14) F ill coolin g syst em (Refer t o 7 - COOLING -
degr ees. STANDARD P ROCE DURE ).
(5) In st a ll st a r t er a n d fa st en er s.
(6) Con n ect exh a u st pipe t o m a n ifold.
(7) Con n ect h ea t er h oses a t en gin e. VALV E T I M I N G
(8) In st a ll fa st en er a t t a ch in g A/C a ccu m u la t or.
(9) In st a ll A/C com pr essor a n d fa st en er s. DESCRIPTION—TIMING DRIVE SYSTEM
(10) In st a ll a ccessor y dr ive belt (Refer t o 7 - Th e t im in g dr ive syst em h a s been design ed t o pr o-
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - vide qu iet per for m a n ce a n d r elia bilit y t o su ppor t a
INSTALLATION). n o n -fre e w h e e lin g en gin e. Specifica lly t h e in t a ke
VALV E T I M I N G (Cont inue d)
va lves a r e n on -fr ee wh eelin g a n d ca n be ea sily da m - sist s of t wo in t egr a l t h ir t y t oot h spr ocket s a n d a fift y
a ged wit h for cefu l en gin e r ot a t ion if ca m sh a ft -t o- t oot h spr ocket t h a t is splin ed t o t h e a ssem bly. Th e
cr a n ksh a ft t im in g is in cor r ect . Th e t im in g dr ive splin e join t is a n on – ser vicea ble pr ess fit a n t i r a t t le
syst em con sist s of a pr im a r y ch a in a n d t wo secon d- t ype. A spir a l r in g is in st a lled on t h e ou t boa r d side of
a r y t im in g ch a in dr ives (F ig. 109). t h e fift y t oot h spr ocket t o pr even t splin e disen ga ge-
m en t . Th e idler spr ocket a ssem bly spin s on a st a t ion -
OPERATION—TIMING DRIVE SYSTEM a r y idler sh a ft . Th e idler sh a ft is pr ess-fit in t o t h e
Th e pr im a r y t im in g ch a in is a sin gle in ver t ed t oot h cylin der block. A la r ge wa sh er on t h e idler sh a ft bolt
t ype. Th e pr im a r y ch a in dr ives t h e la r ge fift y t oot h a n d t h e r ea r fla n ge of t h e idler sh a ft a r e u sed t o con -
idler spr ocket dir ect ly fr om a 25 t oot h cr a n ksh a ft t r ol spr ocket t h r u st m ovem en t . P r essu r ized oil is
spr ocket . P r im a r y ch a in m ot ion is con t r olled by a r ou t ed t h r ou gh t h e cen t er of t h e idler sh a ft t o pr o-
pivot in g lea f spr in g t en sion er a r m a n d a fixed gu ide. vide lu br ica t ion for t h e t wo bu sh in gs u sed in t h e
Th e a r m a n d t h e gu ide bot h u se n ylon pla st ic wea r idler spr ocket a ssem bly.
fa ces for low fr ict ion a n d lon g wea r. Th e pr im a r y Th er e a r e t wo secon da r y dr ive ch a in s, bot h a r e
ch a in r eceives oil spla sh lu br ica t ion fr om t h e secon d- in ver t ed t oot h t ype, on e t o dr ive t h e ca m sh a ft in ea ch
a r y ch a in dr ive a n d oil pu m p lea ka ge. Th e idler SOH C cylin der h ea d. Th er e a r e n o sh a ft speed
spr ocket a ssem bly con n ect s t h e pr im a r y a n d secon d- ch a n ges in t h e secon da r y ch a in dr ive syst em . E a ch
a r y ch a in dr ives. Th e idler spr ocket a ssem bly con - secon da r y ch a in dr ives a t h ir t y t oot h ca m spr ocket
Fig. 109 Timing Drive System

1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 - PRIMARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT 8 - IDLER SPROCKET
SIDE NOT COMMON) 9 - CRANKSHAFT SPROCKET
3 - SECONDARY TENSIONER ARM 10 - PRIMARY CHAIN TENSIONER
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
5 - CHAIN GUIDE 12 - SECONDARY TENSIONER ARM
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
dir ect ly fr om t h e t h ir t y t oot h spr ocket on t h e idler
spr ocket a ssem bly. A fixed ch a in gu ide a n d a h ydr a u -
lic oil da m ped t en sion er a r e u sed t o m a in t a in t en sion
in ea ch secon da r y ch a in syst em . Th e h ydr a u lic t en -
sion er s for t h e secon da r y ch a in syst em s a r e fed pr es-
su r ized oil fr om oil r eser voir pocket s in t h e block.
E a ch t en sion er a lso h a s a m ech a n ica l r a t ch et syst em
t h a t lim it s ch a in sla ck if t h e t en sion er pist on bleeds
down a ft er en gin e sh u t down . Th e t en sion er a r m s
a n d gu ides a lso u t ilize n ylon wea r fa ces for low fr ic-
t ion a n d lon g wea r. Th e secon da r y t im in g ch a in s
r eceive lu br ica t ion fr om a sm a ll or ifice in t h e t en -
sion er s. Th is or ifice is pr ot ect ed fr om cloggin g by a
fin e m esh scr een wh ich is loca t ed on t h e ba ck of t h e
h ydr a u lic t en sion er s.
STANDARD PROCEDURE—ENGINE TIMING

VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
Fig. 110 Engine Top Dead Center (TDC) Indicator

NOTE: Components referred to as left hand or right Mark
hand are as viewed from the drivers position inside 1 - TIMING CHAIN COVER
the vehicle. 2 - CRANKSHAFT TIMING MARKS
NOTE: The blue link plates on the chains and the (5) If on ly on e of t h e ca m sh a ft dr ive gea r s is off
dots on the camshaft drive sprockets may not line a n d t h e ot h er is cor r ect , t h e pr oblem is con fin ed t o
up during the timing verification procedure. The on e secon da r y ch a in . Refer t o Sin gle ca m sh a ft t im -
blue link plates are lined up with the sprocket dots in g, in t h is pr ocedu r e.
only when re-timing the complete timing drive. (6) If bot h ca m sh a ft dr ive gea r V8 m a r ks a r e a t
Once the timing drive is rotated blue link-to-dot t h e t welve o’clock or t h e six o’ clock posit ion t h e
alignment is no longer valid. en gin e ba se t im in g is cor r ect . Rein st a ll t h e cylin der
h ea d cover s.
E n gin e ba se t im in g ca n be ver ified by t h e followin g
pr ocedu r e: SINGLE CAMSHAFT TIMING
(1) Rem ove t h e cylin der h ea d cover s (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD NOTE: to adjust the timing on one camshaft, pre-
COVE R(S) - RE MOVAL). form the following procedure.
(2) Usin g a m ir r or, loca t e t h e TDC a r r ow on t h e
fr on t cover (F ig. 110). Rot a t e t h e cr a n ksh a ft u n t il t h e (1) Usin g Ch a in Ten sion er Wedge, specia l t ool
m a r k on t h e cr a n ksh a ft da m per is a lign ed wit h t h e 8350, st a bilize t h e secon da r y ch a in dr ive (F ig. 112).
TDC a r r ow on t h e fr on t cover. Th e en gin e is n ow a t F or r efer en ce pu r poses, m a r k t h e ch a in -t o-spr ocket
TDC. posit ion (F ig. 112).
(3) Not e t h e loca t ion of t h e V8 m a r k st a m ped in t o (2) Rem ove t h e ca m sh a ft dr ive gea r r et a in in g bolt .
t h e ca m sh a ft dr ive gea r s (F ig. 111). If t h e V8 m a r k (3) Ca r efu lly r em ove t h e ca m sh a ft dr ive gea r fr om
on ea ch ca m sh a ft dr ive gea r is a t t h e t welve o’clock t h e ca m sh a ft .
posit ion , t h e en gin e is a t TDC (cylin der #1) on t h e (4) Re-in dex t h e ca m sh a ft dr ive gea r in t h e ch a in
exh a u st st r oke. If t h e V8 m a r k on ea ch gea r is a t t h e u n t il t h e V8 m a r k is a t t h e sa m e posit ion a s t h e V8
six o’clock posit ion , t h e en gin e is a t TDC (cylin der m a r k on t h e opposit e ca m sh a ft dr ive gea r.
#1) on t h e com pr ession st r oke.
(4) If bot h of t h e ca m sh a ft dr ive gea r s a r e off in NOTE: When gripping the camshaft, place the pliers
t h e sa m e or opposit e dir ect ion s, t h e pr im a r y ch a in or on the tube portion of the camshaft only. Do not
bot h secon da r y ch a in s a r e a t fa u lt . Refer t o Tim in g grip the lobes or the sprocket areas.
Ch a in a n d Spr ocket s pr ocedu r e in t h is sect ion .

(5) Usin g a su it a ble pa ir of a dju st a ble plier s, STANDARD PROCEDURE—MEASURING

r ot a t e t h e ca m sh a ft u n t il t h e a lign m en t dowel on t h e
ca m sh a ft is a lign ed wit h t h e slot in t h e ca m sh a ft TIMING CHAIN WEAR
dr ive gea r (F ig. 113).
NOTE: This procedure must be performed with the
CAUTION: Remove excess oil from camshaft timing chain cover removed.
sprocket retaining bolt before reinstalling bolt. Fail-
(1) Rem ove t h e t im in g ch a in cover. (Refer t o 9 -
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) P osit ion t h e ca m sh a ft dr ive gea r on t o t h e ca m - (2) To det er m in e if t h e secon da r y t im in g ch a in s
sh a ft , r em ove oil fr om bolt t h en in st a ll t h e r et a in in g a r e wor n , r ot a t e t h e en gin e clockwise u n t il m a xim u m
bolt . Usin g Specia l Tools, Spa n n er Wr en ch 6958 wit h t en sion er pist on ext en sion is obt a in ed. Mea su r e t h e
Ada pt er P in s 8346 a n d a su it a ble t or qu e wr en ch , dist a n ce bet ween t h e secon da r y t im in g ch a in t en -
Tigh t en r et a in in g bolt t o 122N·m (90 ft . Lbs.) (F ig. sion er h ou sin g a n d t h e st ep ledge on t h e pist on (F ig.
114) (F ig. 115). 116). Th e m ea su r em en t a t poin t (A) m u st be less
(7) Rem ove specia l t ool 8350. t h a n 15m m (0.5906 in ch es).
(8) Rot a t e t h e cr a n ksh a ft t wo fu ll r evolu t ion s, t h en (3) If t h e m ea su r em en t exceeds t h e specifica t ion
r ever ify t h a t t h e ca m sh a ft dr ive gea r V8 m a r ks a r e t h e secon da r y t im in g ch a in s a r e wor n a n d r equ ir e
in fa ct a lign ed. r epla cem en t . (Refer t o 9 - E NGINE /VALVE TIMING/
(9) In st a ll t h e cylin der h ea d cover s (Refer t o 9 - TIMING BE LT/CH AIN AND SP ROCKE TS -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD RE MOVAL).
NOTE: If the secondary chains are to be replaced
the primary chain and sprockets must also be
replaced.
Fig. 113 Camshaft Dowel To

2 - CAMSHAFT DOWEL
Fig. 115 Camshaft Sprocket Installation—Right

Cylinder Head
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 114 Camshaft Sprocket Left Cylinder Head

1 - TORQUE WRENCH
Fig. 116 Measuring Secondary Timing Chains For

Wear
1 - SECONDARY TENSIONER ARM
2 - SECONDARY CHAIN TENSIONER PISTON
T I M I N G BELT / CH AI N
COV ER(S)
REMOVAL
(1) Discon n ect t h e ba t t er y n ega t ive ca ble.
(3) Discon n ect bot h h ea t er h oses a t t im in g cover.
(4) Discon n ect lower r a dia t or h ose a t en gin e.
(5) Rem ove cr a n ksh a ft da m per (Refer t o 9 -
RE MOVAL).
(6) Rem ove a ccessor y dr ive belt t en sion er a ssem bly
(F ig. 117).
Fig. 118 Timing Chain Cover Fasteners
Fig. 117 Accessory Drive Belt Tensioner

1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER Fig. 119 Timing Chain Cover Fasteners
(6) In st a ll lower r a dia t or h ose.
(7) Rem ove t h e gen er a t or a n d A/C com pr essor. (7) In st a ll bot h h ea t er h oses.
(8) Rem ove cover a n d ga sket (F ig. 118). (8) F ill coolin g syst em (Refer t o 7 - COOLING -
INSTALLATION (9) Con n ect t h e ba t t er y n ega t ive ca ble.
(1) Clea n t im in g ch a in cover a n d block su r fa ce.
In spect cover ga sket a n d r epla ce a s n ecessa r y.
(2) In st a ll cover a n d ga sket . Tigh t en fa st en er s in T I M I N G BELT /CH AI N AN D
sequ en ce a s sh own in (F ig. 119) t o 54 N·m (40 ft . lbs.) SPROCK ET S
.
(3) In st a ll t h e A/C com pr essor a n d gen er a t or.
(4) In st a ll cr a n ksh a ft da m per (Refer t o 9 -
REMOVAL
INSTALLATION).
(5) In st a ll a ccessor y dr ive belt t en sion er a ssem bly.
Tigh t en fa st en er t o 54 N·m (40 ft . lbs.).
(3) Rem ove r igh t a n d left cylin der h ea d cover s (12) Rem ove ca m sh a ft posit ion sen sor fr om r igh t
(Refer t o 9 - E NGINE /CYLINDE R H E AD/CYLIN- cylin der h ea d (F ig. 124).
DE R H E AD COVE R(S) - RE MOVAL).
(4) Rem ove r a dia t or fa n (Refer t o 7 - COOLING/ CAUTION: Care should be taken not to damage
E NGINE /RADIATOR FAN - RE MOVAL). camshaft target wheel. Do not hold target wheel
(5) Rot a t e en gin e u n t il t im in g m a r k on cr a n ksh a ft while loosening or tightening camshaft sprocket.
da m per a lign s wit h TDC m a r k on t im in g ch a in cover Do not place the target wheel near a magnetic
(F ig. 120) (#1 cylin der exh a u st st r oke) a n d t h e ca m - source of any kind. A damaged or magnetized tar-
sh a ft spr ocket “V8” m a r ks a r e a t t h e 12 o’clock posi- get wheel could cause a vehicle no start condition.
t ion (F ig. 121).
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Rem ove left a n d r igh t ca m sh a ft spr ocket bolt s.

(14) Wh ile h oldin g t h e left ca m sh a ft st eel t u be
wit h a dju st a ble plier s, (F ig. 125) r em ove t h e left
ca m sh a ft spr ocket . Slowly r ot a t e t h e ca m sh a ft
a ppr oxim a t ely 15 degr ees clockwise t o a n eu t r a l posi-
t ion .
(15) Wh ile h oldin g t h e r igh t ca m sh a ft st eel t u be
wit h a dju st a ble plier s, (F ig. 126) r em ove t h e r igh t
ca m sh a ft spr ocket . Slowly r ot a t e t h e ca m sh a ft
a ppr oxim a t ely 45 degr ees cou n t er clockwise t o a n eu -
t r a l posit ion .
(16) Rem ove idler spr ocket a ssem bly bolt .
(17) Slide t h e idler spr ocket a ssem bly a n d cr a n k
spr ocket for wa r d sim u lt a n eou sly t o r em ove t h e pr i-
m a r y a n d secon da r y ch a in s.
(18) Rem ove bot h pivot in g t en sion er a r m s a n d
ch a in gu ides.
Fig. 120 Engine Top Dead Center (TDC) Indicator (19) Rem ove ch a in t en sion er.
Mark
1 - TIMING CHAIN COVER INSPECTION
2 - CRANKSHAFT TIMING MARKS In spect t h e followin g com pon en t s:
• Spr ocket s for excessive t oot h wea r. Som e t oot h
(6) Rem ove power st eer in g pu m p. m a r kin gs a r e n or m a l a n d n ot a ca u se for spr ocket
(7) Rem ove a ccess plu gs (2) fr om left a n d r igh t cyl- r epla cem en t .
in der h ea ds for a ccess t o ch a in gu ide fa st en er s (F ig. • Idler spr ocket a ssem bly bu sh in g a n d sh a ft for
122). excessive wea r.
(8) Rem ove t h e oil fill h ou sin g t o ga in a ccess t o t h e • Idler spr ocket a ssem bly splin e join t . Th e join t
r igh t side t en sion er a r m fa st en er. sh ou ld be t igh t wit h n o ba ckla sh or a xia l m ovem en t .
(9) Rem ove cr a n ksh a ft da m per (Refer t o 9 - • Ch a in gu ides a n d t en sion er a r m s. Repla ce t h ese
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R - pa r t s if gr oovin g in pla st ic fa ce is m or e t h a n 1 m m
RE MOVAL) a n d t im in g ch a in cover (Refer t o 9 - (0.039 in .) deep. If pla st ic fa ce is sever ely gr ooved or
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN m elt ed, t h e t en sion er lu be jet m a y be clogged. Th e
COVE R(S) - RE MOVAL). t en sion er sh ou ld be r epla ced.
(10) Colla pse a n d pin pr im a r y ch a in t en sion er • secon da r y ch a in t en sion er pist on a n d r a t ch et in g
(F ig. 123). device. In spect for eviden ce of h ea vy con t a ct bet ween
t en sion er pist on a n d t en sion er a r m . If t h is con dit ion
CAUTION: Plate behind left secondary chain ten- exist t h e t en sion er a n d t en sion er a r m sh ou ld be
sioner could fall into oil pan. Therefore, cover pan r epla ced.
opening. • P r im a r y ch a in t en sion er pla st ic fa ces. Repla ce a s
r equ ir ed (F ig. 127).
(11) Rem ove secon da r y ch a in t en sion er s.

Fig. 122 Cylinder Head Access Plug Location

1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 123 Collapsing And Pinning Primary Chain
Tensioner
INSTALLATION
1 - PRIMARY CHAIN TENSIONER
(1) Usin g a vise, ligh t ly com pr ess t h e secon da r y
ch a in t en sion er pist on u n t il t h e pist on st ep is flu sh
wit h t h e t en sion er body. Usin g a pin or su it a ble t ool,
r elea se r a t ch et pa wl by pu llin g pa wl ba ck a ga in st
spr in g for ce t h r ou gh a ccess h ole on side of t en sion er. body. In st a ll Specia l Tool 8514 lock pin in t o h ole on
Wh ile con t in u in g t o h old pa wl ba ck, P u sh r a t ch et fr on t of t en sion er. Slowly open vise t o t r a n sfer pist on
device t o a ppr oxim a t ely 2 m m fr om t h e t en sion er spr in g for ce t o lock pin (F ig. 128).
Fig. 124 Camshaft Position Sensor—Removal Fig. 126 Camshaft Rotation—Right Side
1 - CRANKSHAFT POSITION SENSOR 1 - ADJUSTABLE PLIERS
2 - CYLINDER HEAD COVER 2 - CAMSHAFT DOWEL
(2) P osit ion pr im a r y ch a in t en sion er over oil pu m p
a n d in ser t bolt s in t o lower t wo h oles on t en sion er
br a cket . Tigh t en bolt s t o 28 N·m (250 in . lbs.).
CAUTION: Overtightening the tensioner arm torx"

bolt can cause severe damage to the cylinder head.
Tighten torx" bolt to specified torque only.
(3) In st a ll r igh t side ch a in t en sion er a r m . Apply

Mopa r ! Lock N, Sea l t o t or x! bolt , t igh t en bolt t o 17
N·m (150 in . lbs.).
NOTE: The silver bolts retain the guides to the cyl-

inder heads and the black bolts retain the guides to
the engine block.
(4) In st a ll t h e left side ch a in gu ide. Tigh t en t h e

bolt s t o 28 N·m (250 in . lbs.).
CAUTION: Overtightening the tensioner arm torx"

bolt can cause severe damage to the cylinder head.
Tighten torx" bolt to specified torque only.
(5) In st a ll left side ch a in t en sion er a r m . Apply

Mopa r ! Lock N, Sea l t o t or x! bolt , t igh t en bolt t o 17
Fig. 125 Camshaft Rotation—Left Side N·m (150 in . lbs.).
1 - CAMSHAFT SPROCKET AND CHAIN (6) In st a ll t h e r igh t side ch a in gu ide. Tigh t en t h e
2 - ADJUSTABLE PLIERS bolt s t o 28 N·m (250 in . lbs.).
3 - CAMSHAFT (7) In st a ll bot h secon da r y ch a in s on t o t h e idler
spr ocket . Align t wo pla t ed lin ks on t h e secon da r y
ch a in s t o be visible t h r ou gh t h e t wo lower open in gs
Fig. 127 Timing Chain System

1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 - PRIMARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT 8 - IDLER SPROCKET
SIDE NOT COMMON) 9 - CRANKSHAFT SPROCKET
3 - SECONDARY TENSIONER ARM 10 - PRIMARY CHAIN TENSIONER
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
5 - CHAIN GUIDE 12 - SECONDARY TENSIONER ARM
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
on t h e idler spr ocket (4 o’clock a n d 8 o’clock). On ce NOTE: It will be necessary to slightly rotate cam-
t h e secon da r y t im in g ch a in s a r e in st a lled, posit ion shafts for sprocket installation.
specia l t ool 8515 t o h old ch a in s in pla ce for in st a lla -
t ion (F ig. 129). (11) Align left ca m sh a ft spr ocket “L” dot t o pla t ed
(8) Align pr im a r y ch a in dou ble pla t ed lin ks wit h lin k on ch a in .
t h e t im in g m a r k a t 12 o’clock on t h e idler spr ocket . (12) Align r igh t ca m sh a ft spr ocket “R” dot t o
Align t h e pr im a r y ch a in sin gle pla t ed lin k wit h t h e pla t ed lin k on ch a in .
t im in g m a r k a t 6 o’clock on t h e cr a n ksh a ft spr ocket
(F ig. 127). CAUTION: Remove excess oil from the camshaft
(9) Lu br ica t e idler sh a ft a n d bu sh in gs wit h clea n sprocket bolt. Failure to do so can result in over-
en gin e oil. torque of bolt resulting in bolt failure.
(10) In st a ll a ll ch a in s, cr a n ksh a ft spr ocket , a n d
(13) Rem ove Specia l Tool 8515, t h en a t t a ch bot h
idler spr ocket a s a n a ssem bly (F ig. 130). Aft er gu id-
spr ocket s t o ca m sh a ft s. Rem ove excess oil fr om bolt s,
in g bot h secon da r y ch a in s t h r ou gh t h e block a n d cyl-
t h en In st a ll spr ocket bolt s, bu t do n ot t igh t en a t t h is
in der h ea d open in gs, a ffix ch a in s wit h a ela st ic st r a p
t im e.
or t h e equ iva len t , Th is will m a in t a in t en sion on
(14) Ver ify t h a t a ll pla t ed lin ks a r e a lign ed wit h
ch a in s t o a id in in st a lla t ion .
t h e m a r ks on a ll spr ocket s a n d t h e “V8” m a r ks on
Fig. 129 Installing Secondary Timing Chains on

Idler Sprocket
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
Fig. 128 Resetting Secondary Chain Tensioners 3 - SECONDARY CHAINS RETAINING PINS (4)
1 - VISE 4 - IDLER SPROCKET
2 - INSERT LOCK PIN 5 - LEFT CAMSHAFT CHAIN
3 - RATCHET PAWL 6 - SPECIAL TOOL 8515
4 - RATCHET
5 - PISTON
ca m sh a ft spr ocket s a r e a t t h e 12 o’clock posit ion (F ig.

127).
CAUTION: Ensure the plate between the left sec-

ondary chain tensioner and block is correctly
installed.
(15) In st a ll bot h secon da r y ch a in t en sion er s.

Tigh t en bolt s t o 28 N·m (250 in . lbs.).
NOTE: Left and right secondary chain tensioners

are not common.
(16) Befor e in st a llin g idler spr ocket bolt , lu br ica t e

wa sh er wit h oil, a n d t igh t en idler spr ocket a ssem bly
r et a in in g bolt t o 34 N·m (25 ft . lbs.).
(17) Rem ove a ll lockin g pin s (3) fr om t en sion er s.
CAUTION: After pulling locking pins out of each Fig. 130 Installing Idler Gear, Primary and
tensioner, DO NOT manually extend the tensioner(s) Secondary Timing Chains
ratchet. Doing so will over tension the chains, 1 - SPECIAL TOOL 8515
resulting in noise and/or high timing chain loads. 2 - PRIMARY CHAIN IDLER SPROCKET
3 - CRANKSHAFT SPROCKET
(18) Usin g Specia l Tool 6958, Spa n n er wit h Ada p-
t or P in s 8346, t igh t en left (F ig. 131) a n d r igh t (F ig.
132). ca m sh a ft spr ocket bolt s t o 122 N·m (90 ft . lbs.). • pr im a r y ch a in idler spr ocket dot is a t 12 o’clock
(19) Rot a t e en gin e t wo fu ll r evolu t ion s. Ver ify t im - (F ig. 127)
in g m a r ks a r e a t t h e follow loca t ion s:
Fig. 132 Tightening Right Side Camshaft Sprocket

Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 131 Tightening Left Side Camshaft Sprocket

Bolt
1 - TORQUE WRENCH
• pr im a r y ch a in cr a n ksh a ft spr ocket dot is a t 6

o’clock (F ig. 127)
• secon da r y ch a in ca m sh a ft spr ocket s “V8” m a r ks
a r e a t 12 o’clock (F ig. 127)
(20) Lu br ica t e a ll t h r ee ch a in s wit h en gin e oil.
(21) Aft er in st a llin g a ll ch a in s, it is r ecom m en ded
t h a t t h e idler gea r en d pla y be ch ecked (F ig. 133).
Th e en d pla y m u st be wit h in 0.10–0.25 m m (0.004–
0.010 in .). If n ot wit h in specifica t ion , t h e idler gea r
(22) In st a ll t im in g ch a in cover (Refer t o 9 -
COVE R(S) - INSTALLATION) a n d cr a n ksh a ft
Fig. 133 Measuring Idler Gear End Play
da m per (Refer t o 9 - E NGINE /E NGINE BLOCK/VI-
BRATION DAMP E R - INSTALLATION). 1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
(23) In st a ll cylin der h ea d cover s (Refer t o 9 -
COVE R(S) - INSTALLATION). NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(24) Coa t t h e la r ge t h r ea ded a ccess plu g wit h (28) In st a ll r a dia t or fa n (Refer t o 7 - COOLING/
Mo p a r! Th re a d S e a la n t w ith Te flo n , t h en in st a ll E NGINE /RADIATOR FAN - INSTALLATION).
in t o t h e r igh t cylin der h ea d a n d t igh t en t o 81 N·m (29) F ill coolin g syst em (Refer t o 7 - COOLING -
(60 ft . lbs.) (F ig. 122). STANDARD P ROCE DURE ).
(25) In st a ll t h e oil fill h ou sin g. (30) Con n ect n ega t ive ca ble t o ba t t er y.
(26) In st a ll a ccess plu g in left cylin der h ea d (F ig.
122).
(27) In st a ll power st eer in g pu m p.

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WJ ENGINE 9-1

ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE 4.7L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

ENGINE - 4.0L INTAKE/EXHAUST VALVES & SEATS

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 51

Fig. 1 Engine Firing Order

DIAGNOSIS AND TESTING—ENGINE

DIAGNOSIS AND TESTING - SERVICE DIAGNOSIS (PERFORMANCE)

CONDITION POSSIBLE CAUSES CORRECTION

2. Corroded or loose battery 2. Clean/tighten suspect battery/

2. No fuel 2. Perform fuel pressure test (Refer

CONDITION POSSIBLE CAUSES CORRECTION

CONDITION POSSIBLE CAUSES CORRECTION

5. Faulty coil rail 5. Test and replace as necessary.

DIAGNOSIS AND TESTING - SERVICE DIAGNOSIS (MECHANICAL)

CONDITION POSSIBLE CAUSES CORRECTION

CONDITION POSSIBLE CAUSES CORRECTION

5. Connecting rod journal out of 5. Replace crankshaft or grind

OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket

EXCESSIVE OIL CONSUMPTION 1. CCV System malfunction 1. (Refer to 25 - EMISSIONS

CONDITION POSSIBLE CAUSES CORRECTION

3. Worn or broken piston rings 3. Hone cylinder bores. Install new

DIAGNOSIS AND TESTING—CYLINDER WARNING: DO NOT REMOVE THE RADIATOR CAP

CONDITION POSSIBLE CAUSE CORRECTION

STANDARD PROCEDURE—CYLINDER BORE

CAUTION: DO NOT use engine or transmission oil,

(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p

Displacement 4.0L (242 cu. in.) Intake

Cooling System Liquid Cooled–Forced Valve Overlap 41.6°

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Exhaust Duration 259.° Taper 0.025 mm (0.001 in.)

Connecting Rod Journal Piston Pin Bore Diameter 23.59 to 23.62 mm

Side Clearance 0.25 to 0.48 mm

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

(120 to 150 psi) VALVES

DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Piston Pin Bore 40.61 to 40.72 mm OIL PUMP

Piston Ring Groove DESCRIPTION N·m Ft. In.

DESCRIPTION N·m Ft. In. DESCRIPTION N·m Ft. In.

Flywheel to Converter 38 28 — INSTALLATION - 4.0L

Fig. 7 RESONATOR CLAMP - 4.0L

Fig. 6 Air Cleaner Assembly —4.0L Engine INSTALLATION - 4.0L

CAUTION: During the final tightening sequence,

(a ) Tigh t en a ll bolt s in sequ en ce (1 t h r ou gh 14)

CAUTION: Engine cylinder head bolts should be

CAUTION: The serpentine drive belt must be routed

Fig. 13 Cylinder Head Cover Gasket Locator Pins at

CLEANING I N TAK E/EX H AU ST VALV ES &

Fig. 16 Measurement of Valve Seat Runout

VALVE STEM-TO-GUIDE CLEARANCE

Fig. 17 Measurement of Valve Guide Bore Diameter

NOTE: Valve seats must be ground after reaming

Fig. 19 Valve and Valve Components

Fig. 18 Measurement of Lateral Movement Of Valve (1) Th or ou gh ly clea n t h e va lve st em s a n d t h e va lve

Fig. 21 Rocker Arms—Typical

Fig. 22 Rocker Arm

Fig. 25 VALVE AND KEEPER CONFIGURATION 4.0L

STANDARD PROCEDURE - VALVE SPRING

(1) Ligh t ly pu sh t h e va lve sea l over t h e va lve st em

Fig. 28 Valve and Valve