1994 JEEP CHEROKEE front

(29) Disconnect the engine speed sensor wire con-
nection.
(30) Remove the exhaust pipe support.
(31) Remove the flywheel/converter housing access
cover.
(32)Vehicles with Automatic Transmission:
(a) Mark the converter and drive plate location.
(b) Remove the converter-to-drive plate bolts.
(33) Remove the upper flywheel/converter housing
bolts and loosen the bottom bolts.
(34) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(35) Lower the vehicle.
(36) Attach a lifting device to the engine.
(37) Raise the engine off the front supports.
(38) Place a support or floor jack under the con-
verter (or flywheel) housing.
(39) Remove the remaining converter (or flywheel)
housing bolts.
(40) Lift the engine out of the engine compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the en-
gine mount cushions from the engine mount bracket
as an aide in alignment of the engine to the trans-
mission.
(2)Vehicles with Manual Transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.
(c) Install and tighten the flywheel housing
lower bolts finger tight.(3)Vehicles with Automatic Transmission:
(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger tight.
(4) Install the engine mount cushions (if removed).
(5) Lower the engine and engine mount cushions
onto the engine compartment brackets. Install the
bolts and finger tighten the nuts.
(6) Remove the engine lifting device.
(7) Raise and support the vehicle.
(8) Install the remaining flywheel/converter hous-
ing bolts. Tighten all bolts to 38 Nzm (28 ft. lbs.)
torque.
(9)Vehicles with Automatic Transmission:
(a) Install the converter-to-drive plate bolts.
(b) Ensure the installation reference marks are
aligned.
(10) Install the flywheel/converter housing access
cover.
(11) Install the exhaust pipe support and tighten
the screw.
(12) Tighten the engine mount-to-bracket bolts.
(13) Connect the engine speed sensor wire connec-
tions and tighten the screws.
(14) Connect the exhaust pipe to the manifold.
(15) Install the starter motor and connect the ca-
ble.
(16) Connect the wires to the starter motor sole-
noid.
(17) Lower the vehicle.
(18) Connect all the vacuum hoses and wire con-
nectors identified during engine removal.
(19) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(20) Install the power brake vacuum check valve
to the booster, if equipped.
(21) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(22) Install the fuel line bracket to the intake
manifold.
(23) Connect the distributor electrical connector
and oil pressure switch connector.
(24) Connect the injection system wire harness
connector on the dash panel.
(25) Connect the line pressure cable (if equipped
with automatic transmission).
(26) Connect the speed control cable, if equipped.
(27) Connect the throttle cable linkages.
Fig. 16 Air Cleaner Assembly & Power Steering
Pump
9 - 56 4.0L ENGINEJ

(20) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(21) Remove the fan shroud screws.
(22) Remove the radiator attaching bolts.
(23) Remove the radiator and fan shroud (Fig. 19).
Refer to Group 7, Cooling System for the proper pro-
cedure.
(24) Remove the fan and spacer or Tempatrol fan
assembly.
(25) Install a 5/16 X 1/2-inch SAE capscrew
through fan pulley into water pump flange. This will
maintain the pulley and water pump in alignment
when crankshaft is rotated.
(26) Remove the power brake vacuum check valve
from the booster, if equipped.
(27) If equipped with power steering (Fig. 19):
(a) Disconnect the hoses from the fittings at the
steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the
system.
(28) Lift the vehicle and support it with support
stands.
(29) Remove the starter motor.
(30) Remove the flywheel housing access cover.
(31) Remove the engine support cushion-to-bracket
through bolts.
(32) Disconnect the exhaust pipe from the mani-
fold.
(33) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(34) Lower the vehicle.
(35) Attach a lifting device to the engine.
(36) Raise the engine off the front supports.
(37) Place a support stand under the flywheel
housing.
(38) Remove the remaining flywheel housing bolts.(39) Lift the engine out of the engine compartment
and install on an engine stand.
INSTALLATION
(1) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(2) Insert the transmission shaft into the clutch
spline.
(3) Align the flywheel housing with the engine.
(4) Install and finger tighten the flywheel housing
lower bolts.
(5) Install the engine support cushions (if re-
moved).
(6) Remove the support stand from beneath the fly-
wheel housing.
(7) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten the nuts.
(8) Remove the engine lifting device.
(9) Raise the vehicle.
(10) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(11) Install the flywheel housing access cover.
(12) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(13) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect the coolant hoses and tighten the
clamps.
(16) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
Fig. 18 Fuel Line Quick-Connect Couplings, Air
Cleaner Assembly, Throttle & Speed Control CablesFig. 19 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Power Steering Pump
9 - 58 4.0L ENGINEJ

LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 12).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Leak-Down
Tester 7980.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di-
ameter ball bearing on the plunger cap of the tappet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. DO NOT tighten
the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal po-
sition.
(6) Adjust the nose of the ram to align the pointer
with the SET mark on the scale of the tester and
tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the
base of the tester clockwise one revolution every 2
seconds.
(9) Observe the leak-down time interval from the
instant the pointer aligns with the START mark on
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-
110 seconds to leak-down. Discard tappets with leak-
down time interval not within this specification.
INSTALLATION
It is not necessary to charge the tappets with en-
gine oil. They will charge themselves within a very
short period of engine operation.(1) Dip each tappet in Mopar Engine Oil Supple-
ment, or equivalent.
(2) Use Hydraulic Valve Tappet Removal/Installa-
tion Tool C-4129-A to install each tappet in the same
bore from where it was originally removed.
(3) Install the exhaust and intake manifolds (refer
to Group 11, Exhaust System and Intake Manifold
for the proper procedure).
(4) Install the engine cylinder head and gasket.
(5) Install the push rods in their original locations.
(6) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(7) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(8) Pour the remaining Mopar Engine Oil Supple-
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
least 1 609 km (1,000 miles). The oil supplement
need not be drained until the next scheduled oil
change.
(9) Install the engine cylinder head cover.
VALVE TIMING
Disconnect the spark plug wires and remove the
spark plugs.
Remove the engine cylinder head cover.
Remove the capscrews, bridge and pivot assembly,
and rocker arms from above the No.1 cylinder.
Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
Rotate the crankshaft until the No.6 piston is at
top dead center (TDC) on the compression stroke.
Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90É.
Install a dial indicator on the end of the No.1 cyl-
inder intake valve push rod. Use rubber tubing to se-
cure the indicator stem on the push rod.
Set the dial indicator pointer at zero.
Rotate the crankshaft clockwise (viewed from the
front of the engine) until the dial indicator pointer
indicates 0.305 mm (0.012 inch) travel distance (lift).
The timing notch index on the vibration damper
should be aligned with the TDC mark on the timing
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
the camshaft because of pin failure. A spring pin is
available for service replacement.
Fig. 12 Leak-Down Tester 7980
9 - 66 4.0L ENGINEJ

(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and
generator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine. Make sure the tension spring and thrust
pin do not fall out of the preload bolt.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 4).
CLEANING
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
INSTALLATION
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward
the inside of the cover. Support the cover at the seal
area while installing the seal. Force it into position
with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
(3) Position the timing case cover on the oil pan
gasket and the cylinder block. Make sure the tension
spring and thrust pin are in place in the camshaft
preload bolt.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 5).
(5) Install the timing case cover-to-cylinder block
and the oil pan-to-timing case cover bolts.
(6) Tighten the 1/4 inch cover-to-block bolts to 7
Nzm (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 Nzm (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 14 Nzm
(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 Nzm (156 in. lbs.) torque.
(7) Remove the cover alignment tool.(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(10) Install the A/C compressor (if equipped) and
generator bracket assembly.
(11) Install the engine fan and hub assembly and
shroud.
(12) Install the serpentine drive belt and tighten to
obtain the specified tension.
(13) Connect negative cable to battery.TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud.
(3) Remove the serpentine drive belt.
(4) Remove the crankshaft vibration damper.
(5) Remove the timing case cover.
(6) Rotate crankshaft until the ``0'' timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 6).
(7) Remove the oil slinger from the crankshaft.
(8) Remove the tension spring and thrust pin from
the preload bolt (Fig. 7). Remove the camshaft
sprocket retaining preload bolt and washer.
(9) Remove the crankshaft sprocket, camshaft
sprocket and timing chain as an assembly.
Installation of the timing chain with the timing
marks on the crankshaft and camshaft sprockets
properly aligned ensures correct valve timing. A
worn or stretched timing chain will adversely affect
valve timing. If the timing chain deflects more than
Fig. 4 Timing Case Cover Components
Fig. 5 Timing Case Cover Alignment and Seal
Installation Tool 6139
9 - 68 4.0L ENGINEJ

(5) Remove the distributor cap and mark the posi-
tion of the rotor.
(6) Remove the distributor and ignition wires.
(7) Remove the engine cylinder head cover.
(8) Remove the rocker arms, bridges and pivots.
(9) Remove the push rods.
(10) Remove the engine cylinder head and gasket.
(11) Remove the hydraulic valve tappets from the
engine cylinder head.
(12) Remove the vibration damper.
(13) Remove the timing case cover.
(14) Remove the timing chain and sprockets.
(15) Remove the front bumper and/or grille, as re-
quired.
(16) Remove the camshaft (Fig. 9).
INSPECTION
Inspect the cam lobes for wear.
Inspect the bearing journals for uneven wear pat-
tern or finish.
Inspect the bearings for wear.
Inspect the distributor drive gear for wear.
If the camshaft appears to have been rubbing
against the timing case cover, examine the oil pres-
sure relief holes in the rear cam journal. The oil
pressure relief holes must be free of debris.
INSTALLATION
(1) Lubricate the camshaft with Mopar Engine Oil
Supplement, or equivalent.
(2) Carefully install the camshaft to prevent dam-
age to the camshaft bearings (Fig. 9).
(3) Install the timing chain, crankshaft sprocket
and camshaft sprocket with the timing marks
aligned.
(4) Install the camshaft sprocket retaining preload
bolt. Tighten the bolt to 108 Nzm (80 ft. lbs.) torque.
(5) Lubricate the tension spring, the thrust pin
and the pin bore in the preload bolt with Mopar En-
gine Oil Supplement, or equivalent. Install the
spring and thrust pin in the preload bolt head.(6) Install the timing case cover with a replace-
ment oil seal (Fig. 10). Refer to Timing Case Cover
Installation.
(7) Install the vibration damper (Fig. 10).
(8) Install the hydraulic valve tappets.
(9) Install the engine cylinder head.
(10) Install the push rods.
(11) Install the rocker arms and pivot and bridge
assemblies. Tighten each of the capscrews for each
bridge alternately, one turn at a time, to avoid dam-
aging the bridge.
(12) Install the engine cylinder head cover.
(13) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys-
tem for the proper procedure).
(14) Rotate the crankshaft until the No.1 piston is
at the TDC position on the compression stroke.
(15) Install the distributor, cap and ignition wires.
Install the distributor so that the rotor is aligned
with the mark made during removal. The rotor
should be aligned with the No.1 cylinder spark plug
terminal on the cap when the distributor housing is
fully seated on the cylinder block.
During installation, lubricate the hydraulic
valve tappets and all valve components with Mo-
par Engine Oil Supplement, or equivalent. The
Mopar Engine Oil Supplement, or equivalent
must remain with the engine oil for at least 1 609
km (1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(16) Install the A/C condenser and receiver/drier
assembly, if equipped (refer to Group 24, Heating
and Air Conditioning).
CAUTION: Both service valves must be opened be-
fore the air conditioning system is operated.
(17) Install the radiator, connect the hoses and fill
the cooling system to the specified level (refer to
Group 7, Cooling System for the proper procedure).
Fig. 9 Camshaft
Fig. 10 Timing Case Cover Components
9 - 70 4.0L ENGINEJ

(18) Check the ignition timing and adjust as nec-
essary.
(19) Install the grille and bumper, if removed.
(20) Connect negative cable to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain the radiator. DO NOT waste reusable
coolant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
(4) Disconnect the radiator overflow tube, radiator
hoses, automatic transmission fluid cooler pipes (if
equipped).
(5) Remove the radiator.
(6) If equipped with air conditioning:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpentine drive
belt idler pulley.
(b) Disconnect and remove the generator.
(c) Remove the A/C condenser attaching bolts
and move the condenser and receiver/drier assem-
bly up and out of the way.
(7) Remove the serpentine drive belt.
(8) Remove the crankshaft vibration damper.
(9) Remove the timing case cover. Clean the gas-
ket material from the cover.
(10) Remove the thrust pin and tension spring
from the preload bolt head.
(11) Rotate crankshaft until the crankshaft
sprocket timing mark is closest to and on the center
line with the camshaft sprocket timing mark (Fig.
11).
(12) Remove the camshaft sprocket preload retain-
ing bolt and washer.
(13) Remove the crankshaft oil slinger.
(14) Remove the sprockets and chain as an assem-
bly.
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(15) Inspect the damaged camshaft pin.
(16) If the pin is a spring-type pin, remove the bro-
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.(17) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: Cover the opened oil pan area to prevent
metal chips from entering the pan.
(18) Drill into the pin center witha4mm(5/32
inch) drill bit.
(19) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled, bab-
bitt-lined bearings that are pressed into the cylinder
block and then line reamed. The camshaft bearing
bores and bearing diameters are not the same size.
They are stepped down in 0.254 mm (0.010 inch) in-
crements from the front bearing (largest) to the rear
bearing (smallest). This permits easier removal and
installation of the camshaft. The camshaft bearings
are pressure lubricated.
It is not advisable to attempt to replace cam-
shaft bearings unless special removal and instal-
lation tools are available.
Camshaft end play is maintained by the load
placed on the camshaft by the sprocket preload bolt
tension spring and thrust pin.
INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install the camshaft sprocket, crankshaft
sprocket and timing chain with the timing marks
aligned (Fig. 11).
(5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
sprocket timing mark as shown in Fig. 12. Count the
Fig. 11 Timing Chain AlignmentÐTypical
J4.0L ENGINE 9 - 71

number of chain pins between the timing marks of
both sprockets. There must be 15 pins.
(6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket preload bolt to
108 Nzm (80 ft. lbs.) torque.
(8) Check the valve timing.
(9) Lubricate the tension spring, the thrust pin
and the pin bore in the preload bolt with Mopar En-
gine Oil Supplement, or equivalent. Install the
spring and thrust pin in the preload bolt head.
(10) Coat both sides of the replacement timing case
cover gasket with gasket sealer. Applya3mm(1/8
inch) bead of Mopar Silicone Rubber Adhesive Seal-
ant, or equivalent to the joint formed at the oil pan
and cylinder block.
(11) Position the timing case cover on the oil pan
gasket and the cylinder block.
(12) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 13).
(13) Install the timing case cover-to-cylinder block
bolts. Install the oil pan-to-timing case cover bolts.
(14) Tighten the 1/4 inch cover-to-block bolts to 7
Nzm (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 Nzm (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 14 Nzm
(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 Nzm (156 in. lbs.) torque.
(15) Remove the cover alignment tool and install a
replacement oil seal into the cover.
(16) Install the vibration damper on the crank-
shaft.(17) Lubricate and tighten the damper bolt to 108
Nzm (80 ft. lbs.) torque.
(18) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive
belt idler pulley.
(b) Install the generator.
(c) Install the A/C condenser and receiver/drier
assembly.
(19) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(20) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(21) Install the fan and shroud.
(22) Connect negative cable to battery.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Remove the oil pan drain plug and drain the
engine oil.
(4) Disconnect the exhaust pipe at the exhaust
manifold.
(5) Disconnect the exhaust hanger at the catalytic
converter and lower the pipe.
(6) Remove the starter motor.
(7) Remove the engine flywheel/transmission
torque converter housing access cover.
(8) If equipped with an oil level sensor, disconnect
the sensor.
(9) Position a jack stand directly under the engine
vibration damper.
(10) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(11) Remove the engine mount through bolts.
Fig. 12 Verify Crankshaft/Camshaft
InstallationÐTypical
Fig. 13 Timing Case Cover Alignment and Seal
Installation Tool 6139
9 - 72 4.0L ENGINEJ

INSPECTIONÐCONNECTING ROD
CONNECTING ROD BEARINGS
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Figs. 3 and 4). Check the bear-
ings for normal wear patterns, scoring, grooving, fa-
tigue and pitting (Fig. 5). Replace any bearing that
shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.CONNECTING RODS
Misaligned or bent connecting rods can cause ab-
normal wear on pistons, piston rings, cylinder walls,
connecting rod bearings and crankshaft connecting
rod journals. If wear patterns or damage to any of
these components indicate the probability of a mis-
aligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe the oil from the connecting rod journal.
(2) Use short rubber hose sections over rod bolts
during installation.
(3) Lubricate the upper bearing insert and install
in connecting rod.
(4) Use piston ring compressor to install the rod
and piston assemblies. The oil squirt holes in the
rods must face the camshaft. The arrow on the piston
crown should point to the front of the engine (Fig. 6).
Verify that the oil squirt holes in the rods face the
camshaft and that the arrows on the pistons face the
front of the engine.
(5) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(6) Install bearing cap and connecting rod on the
journal and tighten nuts to 45 Nzm (33 ft. lbs.)
torque. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(7) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 7). Refer to En-
gine Specifications for the proper clearance.Plasti-
gage should indicate the same clearance across
the entire width of the insert. If the clearance
varies, it may be caused by either a tapered
Fig. 3 Connecting Rod Bearing Inspection
Fig. 4 Locking Tab Inspection
Fig. 5 Scoring Caused by Insufficient Lubrication or
by Damaged Crankshaft Pin Journal
Fig. 6 Rod and Piston Assembly Installation
J4.0L ENGINE 9 - 75