1995 JEEP YJ drain bolt

INSTALLATIONÐYJ VEHICLES
(1)MANUAL TRANSMISSION:
(a) Position the torque arm bracket to the trans-
mission. Install the bolts and tighten to 54 Nzm (40
ft. lbs.) torque.
(b) Position the support cushion onto the torque
arm bracket. Install the nuts and tighten to 54 Nzm
(40 ft. lbs.) torque.
(c) Position the insulator stud assembly and up-
per nut (Fig. 11). Position the skid plate to the
studs of the support cushion and the insulator stud
(Fig. 11). Install the support cushion stud nuts and
tighten to 54 Nzm (40 ft. lbs.) torque. Install the
lower stud nut and tighten the upper and lower in-
sulator stud nuts to 41 Nzm (30 ft. lbs.) torque.
(2)AUTOMATIC TRANSMISSION:
(a) Position the torque arm bracket to the trans-
mission. Install the bolts and tighten to 54 Nzm (40
ft. lbs.) torque.
(b) Position the support cushion onto the torque
arm bracket. Install the bolts and nuts and tighten
to 54 Nzm (40 ft. lbs.) torque.
(c) Position the skid plate to the studs of the sup-
port cushion and install the nuts. Tighten the support
cushion stud nuts to 54 Nzm (40 ft. lbs.) torque.
(3) Install the skid plate bolts to the sill and
tighten to 88 Nzm (65 ft. lbs.) torque.
(4) Remove the transmission support.
(5) Lower the vehicle.
(6) Connect negative cable to battery.
ENGINE ASSEMBLYÐXJ VEHICLES
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste usable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(4) Remove the lower radiator hose.
(5) Remove the upper radiator hose and coolant re-
covery hose (Fig. 13).
Fig. 11 Rear MountÐYJ Vehicles (Manual
Transmission)Fig. 12 Rear MountÐYJ Vehicles (Automatic
Transmission)
J4.0L ENGINE 9 - 59

(6) Remove upper radiator support retaining bolts
and remove radiator support.
(7) Remove the fan shroud (Fig. 13) and electric
cooling fan.
(8) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(9) Disconnect radiator fan switch wire connector.
(10)Vehicles with Air Conditioning:
(a) Discharge the A/C condenser.
(b) Remove the service valves and cap the com-
pressor ports.
(11) Remove the radiator or radiator and con-
denser (if equipped with A/C).
(12) Remove the fan assembly from the idler pul-
ley.
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump (Figs. 13 and
14).
(14) Disconnect the throttle linkages (Fig. 15).
(15) Disconnect the speed control cable (if
equipped)Ð(Fig. 15).(16) Disconnect the line pressure cable (if equipped
with automatic transmission).
(17) Disconnect injection system wire harness con-
nector at the dash panel.
(18) Disconnect the distributor electrical connec-
tion and the oil pressure switch connector.
(19) Perform the Fuel System Pressure Release
procedure (refer to Group 14, Fuel System).
(20) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 15). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(21) Remove the fuel line bracket from the intake
manifold.
(22) Remove the air cleaner assembly (Fig. 16).
(23) Remove the power brake vacuum check valve
from the booster, if equipped.
(24) If equipped with power steering (Fig. 16):
(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.
(25) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(26) Raise and support the vehicle.
(27) Disconnect the wires from the starter motor
solenoid.
(28) Remove the starter motor.
Fig. 13 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
Fig. 14 Heater Hoses (RH Drive Vehicle)
Fig. 15 Accelerator Cable, Speed Control Cable,
Automatic Transmission Control Cable & Quick-
Connect Fuel Lines
9 - 60 4.0L ENGINEJ

(18) Disconnect the oxygen sensor wire connector.
(19) Remove the upper radiator hose and coolant
recovery hose (Fig. 19).
(20) Disconnect lower radiator hoses at the radia-
tor.
(21) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(22) Remove the fan shroud screws.
(23) Remove the radiator attaching bolts.
(24) Remove the radiator and fan shroud (Fig. 19).
Refer to Group 7, Cooling System for the proper pro-
cedure.
(25) Remove the fan and spacer or Tempatrol fan
assembly.
(26) 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.
(27) Remove the power brake vacuum check valve
from the booster, if equipped.
(28) 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.
(29) Lift the vehicle and support it with support
stands.
(30) Remove the starter motor.
(31) Remove the flywheel housing access cover.
(32) Remove the engine support cushion-to-bracket
through bolts.
(33) Disconnect the exhaust pipe from the mani-
fold.
(34) Remove the upper flywheel housing bolts and
loosen the bottom 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 stand under the flywheel
housing.
(39) Remove the remaining flywheel housing bolts.
(40) 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
flywheel 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.
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
J4.0L ENGINE 9 - 63

LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 5).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Leak-Down
Tester.
(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 push rods in their original locations.
(4) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(5) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(6) 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.
(7) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside.
(b) Remove the air conditioner compressor
bracket bolts from the engine cylinder head.
(c) Loosen the through bolt at the bottom of the
bracket.
Fig. 5 Leak-Down Tester
J4.0L ENGINE 9 - 67

properly aligned ensures correct valve timing. A worn
or stretched timing chain will adversely affect valve
timing. If the timing chain deflects more than 12.7
mm (1/2 inch) replace it. The correct timing chain
has 48 pins. A chain with more than 48 pins will
cause excessive slack.
INSTALLATION
Assemble the timing chain, crankshaft sprocket
and camshaft sprocket with the timing marks
aligned (Fig. 5).
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in the keyway on the crankshaft, install
the assembly on the crankshaft and camshaft.
(2) Install the camshaft sprocket retaining preload
bolt and washer (Fig. 7). Tighten the preload bolt to
108 Nzm (80 ft. lbs.) torque.
(3) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
sprocket timing mark as shown in Fig. 8. Count the
number of chain pins between the timing marks of
both sprockets. There must be 15 pins.
(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover.
(6) Lubricate the tension spring, thrust pin and
pin bore in the preload bolt with Mopar Engine Oil
Supplement, or equivalent. Install the spring and
thrust pin in the preload bolt head (Fig. 6).
(7) Install the timing case cover and gasket.
(8) With the key installed in the crankshaft key-
way, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(9) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys-
tem for the proper procedure).
(10) Install the fan and hub (or Tempatrol fan) as-
sembly. Install the shroud.
(11) Connect negative cable to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. RE-
LEASE THE PRESSURE BEFORE REMOVING THE
DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Disconnect negative cable from battery.
(2) Drain the cooling system. DO NOT waste reus-
able coolant. If the solution is clean, drain it into a
clean container for reuse.
(3) Remove the radiator or radiator and condenser,
if equipped with A/C (refer to Group 7, Cooling Sys-
tem for the proper procedure).
(4) Remove the air conditioner condenser and re-
ceiver/drier assembly as a charged unit, if equipped
(refer to Group 24, Heating and Air Conditioning).
(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. 8).
Fig. 6 Camshaft Sprocket Preload Bolt
Fig. 7 Verify SprocketÐChain InstallationÐTypical
9 - 74 4.0L ENGINEJ

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. 8).
(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. 9). Refer to Timing Case Cover In-
stallation.
(7) Install the vibration damper (Fig. 9).
(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) Position the oil pump gear. Refer to Distribu-
tor in the Component Removal/Installation section of
Group 8D, Ignition Systems.(14) Install the distributor and ignition wires. Re-
fer to Distributor in the Component Removal/Instal-
lation section of Group 8D, Ignition Systems.
(13) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys-
tem for the proper procedure).
During installation, lubricate the hydraulic
valve tappets and all valve components with
Mopar Engine Oil Supplement, or equivalent.
The Mopar Engine Oil Supplement, or equiva-
lent 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).
(18) Check the ignition timing and adjust as neces-
sary.
(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.
Fig. 9 Timing Case Cover ComponentsFig. 8 Camshaft
J4.0L ENGINE 9 - 75

(12) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 12).
(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 and 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.
(12) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(13) Remove the oil pan bolts. Carefully slide the
oil pan and gasket to the rear. If equipped with an oil
level sensor, take care not to damage the sensor.
CLEANING
Clean the block and pan gasket surfaces.
INSTALLATION
(1) Fabricate 4 alignment dowels from 1/4 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier in-
stallation and removal with a screwdriver (Fig. 1).
(2) Install two dowels in the timing case cover. In-
stall the other two dowels in the cylinder block (Fig.
2).
Fig. 11 Verify CrankshaftÐCamshaft InstallationÐ
Typical
Fig. 12 Timing Case Cover Alignment and Seal
Installation Tool 6139
J4.0L ENGINE 9 - 77

(3) Slide the one-piece gasket over the dowels and
onto the block and timing case cover.
(4) Position the oil pan over the dowels and onto
the gasket. If equipped with an oil level sensor, take
care not to damage the sensor.
(5) Install the 1/4 inch oil pan bolts. Tighten these
bolts to 14 Nzm (120 in. lbs.) torque. Install the 5/16
inch oil pan bolts (Fig. 3). Tighten these bolts to 18
Nzm (156 in. lbs.) torque.
(6) Remove the dowels. Install the remaining 1/4
inch oil pan bolts. Tighten these bolts to 14 Nzm (120
in. lbs.) torque.(7) Lower the engine until it is properly located on
the engine mounts.
(8) Install the through bolts and tighten the nuts.
(9) Lower the jack stand and remove the piece of
wood.
(10) Install the engine flywheel and transmission
torque converter housing access cover.
(11) Install the engine starter motor.
(12) Connect the exhaust pipe to the hanger and to
the gine exhaust manifold.
(13) Install the oil pan drain plug (Fig. 3). Tighten
the plug to 34 Nzm (25 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect negative cable to battery.
(16) Fill the oil pan with engine oil to the specified
level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(18) Start the engine and inspect for leaks.
Fig. 1 Fabrication of Alignment Dowels
Fig. 2 Position of Dowels in Cylinder Block
Fig. 3 Position of 5/16 inch Oil Pan Bolts
9 - 78 4.0L ENGINEJ