2002 JEEP GRAND CHEROKEE rear main bearing cap

REMOVAL
REMOVAL - CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled,
babbitt-lined bearings that are pressed into the cyl-
inder 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) increments from the front bearing (larg-
est) to the rear bearing (smallest). This permits eas-
ier removal and installation of the camshaft. The
camshaft bearings are pressure lubricated. Camshaft
end play is maintained by the thrust plate.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
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) Using Special tool 8544 Camshaft Bushing
Remover Installer, remove the camshaft bearings.
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) Disconnect negative cable from battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL) and condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL), if
equipped with A/C.
(4) Remove the engine cylinder head cover (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(5) Remove the rocker arms, bridges and pivots
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL).
(6) Remove the push rods.
(7) Remove the engine cylinder head and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - REMOV-
AL).
(8) Remove the hydraulic valve tappets from the
engine cylinder block (Refer to 9 - ENGINE/ENGINE
BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) -
REMOVAL).
(9) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(10) Remove the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Rotate the crankshaft until the crankshaft
sprocket timing mark is aligned on centerline with
the camshaft sprocket timing mark (Fig. 32).
(12) Remove the timing chain and sprockets (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - REMOVAL).
(13) Remove the front bumper and/or grille, as
required.
(14) Remove the two thrust plate retaining screws,
thrust plate and camshaft (Fig. 31).
INSPECTION
INSPECTION - CAMSHAFT BEARINGS
(1) Inspect the bearing journals for uneven wear
pattern or finish.
(2) Inspect the bearings for wear.
INSPECTION - CAMSHAFT
(1) Inspect the cam lobes for wear.
(2) Inspect the camshaft position sensor drive gear
for wear.
(3) If the camshaft appears to have been rubbing
against the thrust washer, examine the oil pressure
Fig. 30 CamshaftÐTypical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
WJENGINE - 4.0L 9 - 31
CAMSHAFT & BEARINGS (Continued)

is needed to provide the correct clearance. Refer to
CONNECTING ROD BEARING FITTING CHART .
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange53.2079 - 53.1901 mm
Yellow - StandardBlue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11)FOR EXAMPLE:If the initial clearance was
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch)
undersize inserts would reduce the clearance by
0.025 mm (0.001 inch). The clearance would be 0.002
inch and within specification. A 0.051 mm (0.002
inch) undersize insert would reduce the initial clear-
ance an additional 0.013 mm (0.0005 inch). The
clearance would then be 0.038 mm (0.0015 inch).
(12) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(13) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 45 N´m (33 ft. lbs.) torque.
SIDE CLEARANCE MEASUREMENT
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 40).
(Refer to 9 - ENGINE - SPECIFICATIONS). Replace
the connecting rod if the side clearance is not within
specification.
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design
with eight counterweights for balancing purposes.The crankshaft is supported by seven select main
bearings with the number three serving as the thrust
washer location. The main journals of the crankshaft
are cross drilled to improve rod bearing lubrication.
The select fit main bearing markings are located on
the crankshaft counter weights. The crankshaft rear
oil seal is a two piece design. The front oil seal is a
one piece design retained in the timing chain cover
(Fig. 41).
Fig. 40 Checking Connecting Rod Side Clearance -
Typical
WJENGINE - 4.0L 9 - 35
CONNECTING ROD BEARINGS (Continued)

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to indicate the for-
ward position. The upper main bearing inserts are
grooved to provide oil channels while the lower
inserts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
for engine production.
The main bearing journal size (diameter) is identi-
fied by a color-coded paint mark (Fig. 42)on the adja-
cent cheek or counterweight towards the rear of the
crankshaft (flange end). The rear main journal, is
identified by a color-coded paint mark on the crank-
shaft rear flange.
When required, upper and lower bearing inserts of
different sizes may be used as a pair. A standard size
insert is sometimes used in combination with a 0.025
mm (0.001 inch) undersize insert to reduce the clear-
ance by 0.013 mm (0.0005 inch).Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.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).
Once the bearings have been properly fitted, (Refer
to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT
MAIN BEARINGS - INSTALLATION).
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When using Plastigage, check only one bearing
clearance at a time.
Install the grooved main bearings into the cylinder
block and the non-grooved bearings into the bearing
caps.
Install the crankshaft into the upper bearings dry.
Place a strip of Plastigage across full width of the
crankshaft journal to be checked.
Install the bearing cap and tighten the bolts to 108
N´m (80 ft. lbs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the bearing cap. Determine the amount of
clearance by measuring the width of the compressed
Plastigage with the scale on the Plastigage envelope
(Fig. 43). (Refer to 9 - ENGINE - SPECIFICATIONS)
for the proper clearance.
Plastigage should indicate the same clearance
across the entire width of the insert. If clearance var-
ies, it may indicate a tapered journal or foreign
material trapped behind the insert.
If the specified clearance is indicated and there are
no abnormal wear patterns, replacement of the bear-
ing inserts is not necessary. Remove the Plastigage
from the crankshaft journal and bearing insert. Pro-
ceed to (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT MAIN BEARINGS -
INSTALLATION).
If the clearance exceeds specification, install a pair
of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ-
ous steps.
The clearance indicate with the 0.025 mm (0.001
inch) undersize insert pair installed will determine if
this insert size or some other combination will pro-
vide the specified clearance.FOR EXAMPLE:If the
clearance was 0.0762 mm (0.003 inch) originally, a
pair of 0.0254 mm (0.001 inch) undersize inserts
would reduce the clearance by 0.0254 mm (0.001
inch). The clearance would then be 0.0508 mm (0.002
inch) and within the specification. A 0.051 mm (0.002
inch) undersize bearing insert and a 0.0254 mm
(0.001 inch) undersize insert would reduce the origi-
Fig. 41 Crankshaft with Select Fit Marking Location
1 - 1/4º LETTERS
2 - (ROD)
3 - (MAIN)
9 - 36 ENGINE - 4.0LWJ
CRANKSHAFT (Continued)

INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 47). In general the
lower bearing half will have a heaver wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
INSTALLATION
(1) Lubricate the bearing surface of each insert
with engine oil.
(2) Loosen all the main bearing caps. Install the
main bearing upper inserts.
(3) Install the lower bearing inserts into the main
bearing caps.
(4) On the rear main cap, apply MopartGasket
Maker sealer on both sides of cylinder block as
shown in (Fig. 48). The dab of sealer should be 3 mm
(0.125 in.) in diameter.
(5) Apply MopartGasket Maker on the rear bear-
ing cap. The bead should be 2.3 mm (0.09 in.) in
diameter. DO NOT apply sealer to the lip of the seal.
(6) Install the main bearing cap(s) and lower
insert(s).
(7) Tighten the bolts of caps 1, 2, 4, 5, 6, and 7 to
54 N´m (40 ft. lbs.) torque. Now tighten these bolts to
95 N´m (70 ft. lbs.) torque. Finally, tighten these
bolts to 108 N´m (80 ft. lbs.) torque.(8) Push the crankshaft forward and backward.
Load the crankshaft front or rear and tighten cap
bolt No.3 to 54 N´m (40 ft. lbs.) torque. Then tighten
to 95 N´m (70 ft. lbs.) torque and finally tighten to
108 N´m (80 ft. lbs.) torque.
(9) Rotate the crankshaft after tightening each
main bearing cap to ensure the crankshaft rotates
freely.
(10) Check crankshaft end play. Crankshaft end
play is controlled by the thrust bearing which is
flange and installed at the No.2 main bearing posi-
tion.
(a) Attach a magnetic base dial indicator to the
cylinder block at either the front or rear of the
engine.
(b) Position the dial indicator rod so that it is
parallel to the center line of the crankshaft.
(c) Pry the crankshaft forward, position the dial
indicator to zero.
(d) Pry the crankshaft forward and backward.
Note the dial indicator readings. End play is the
difference between the high and low measurements
(Fig. 49). Correct end play is 0.038-0.165 mm
(0.0015-0.0065 inch). The desired specifications are
0.051-0.064 mm (0.002-0.0025 inch).
Fig. 47 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
Fig. 48 Location of Sealer
1-DOWEL
2-SEALER LOCATIONS
3-CYLINDER BLOCK
4-HALFWAY BETWEEN
5-REAR FACE OF CYLINDER BLOCK
6-3mm (0.125 in.)
9 - 40 ENGINE - 4.0LWJ
CRANKSHAFT MAIN BEARINGS (Continued)

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
The crankshaft rear main bearing oil seal consists
of two half pieces of viton with a single lip that effec-
tively seals the rear of the crankshaft. Replace the
upper and lower seal halves as a unit to ensure leak-
free operation.
(1) Remove transmission inspection cover.
(2) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(3) Remove main bearing cap brace.
(4) Remove rear main bearing cap (No.7).
(5) Push upper seal out of the groove. Ensure that
the crankshaft and seal groove are not damaged.
(6) Remove lower half of the seal from the bearing
cap.
INSTALLATION
The crankshaft rear main bearing oil seal consists
of two half pieces of viton with a single lip that effec-
tively seals the rear of the crankshaft. Replace the
upper and lower seal halves as a unit to ensure leak-
free operation.
(1) Wipe the seal surface area of the crankshaft
until it is clean.
(2) Apply a thin coat of engine oil.
(3) Coat lip of the seal with engine oil.
(4) Carefully position the upper seal into the
groove in the cylinder block. The lip of the seal faces
toward the front of the engine.
(5) Apply MopartGasket Maker sealer on both
sides of cylinder block as shown in (Fig. 51). The dab
of sealer should be 3 mm (0.125 in.) in diameter.
(6) Apply MopartGasket Maker on the rear bear-
ing cap (Fig. 51). The bead should be 2.3 mm (0.09
in.) in diameter. DO NOT apply sealer to the lip of
the seal.
(7) Position the lower seal into the bearing cap
recess and seat it firmly. Be sure the seal is flush
with the cylinder block pan rail.
(8) Coat the outer curved surface of the lower seal
with soap and the lip of the seal with engine oil.
(9) Install the rear main bearing cap. DO NOT
strike the cap more than twice for proper engage-
ment.
(10) Tighten all main bearing bolts to 108 N´m (80
ft. lbs.) torque.
(11) Install the main bearing cap brace. Tighten
nuts to 47 N´m (35 ft. lbs.).
(12) Install the oil pan gasket and oil pan (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).(13) Apply MopartSilicone Rubber Adhesive Seal-
ant on cylinder block to rear main bearing cap cor-
ners and cylinder block to front cover joints (four
places) (Fig. 52)
(14) Install transmission inspection cover.
Fig. 51 Location of Sealer
1-DOWEL
2-SEALER LOCATIONS
3-CYLINDER BLOCK
4-HALFWAY BETWEEN
5-REAR FACE OF CYLINDER BLOCK
6-3mm (0.125 in.)
Fig. 52 Oil Pan
1 - SEALER LOCATIONS
9 - 42 ENGINE - 4.0LWJ

(11) Lower the vehicle until it is about 2 feet from
the floor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assistant push the piston and con-
necting rod assemblies up and through the top of the
cylinder bores (Fig. 60).
INSTALLATION
(1) Clean the cylinder bores thoroughly. Apply a
light film of clean engine oil to the bores with a clean
lint-free cloth.
(2) Install the piston rings on the pistons if
removed (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON RINGS - STANDARD PROCEDURE).
(3) Lubricate the piston and rings with clean
engine oil.
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.(4) Use a piston ring compressor to install the con-
necting rod and piston assemblies through the top of
the cylinder bores (Fig. 61).
(5) Ensure the arrow on the piston top points to
the front of the engine (Fig. 61).
(6) Raise the vehicle.
(7) Each bearing insert is fitted to its respective
journal to obtain the specified clearance between the
bearing and the journal. In production, the select fit
is obtained by using various-sized, color-coded bear-
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
(8) The rod journal is identified during the engine
production by a color-coded paint mark on the adja-
cent cheek or counterweight toward the flange (rear)
end of the crankshaft. The color codes used to indi-
cate journal sizes are listed in the Connecting Rod
Bearing Fitting Chart.
(9) When required, upper and lower bearing
inserts of different sizes may be used as a pair (refer
to Connecting Rod Bearing Fitting Chart). A stan-
dard size insert is sometimes used in combination
with a 0.025 mm (0.001 inch) undersize insert to
reduce clearance 0.013 mm (0.0005 inch).
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) Install the connecting rod bearing caps and
inserts in the same positions as removed.
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) Install main bearing cap brace (Fig. 58).
Tighten nuts to 47 N´m (35 ft. lbs.).
Fig. 60 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - BLOCK
Fig. 61 Rod and Piston Assembly Installation
9 - 46 ENGINE - 4.0LWJ
PISTON & CONNECTING ROD (Continued)

crankshaft is drilled internally to pass oil from the
main bearing journals (except number 4 main bear-
ing journal) to the connecting rod journals. Each con-
necting rod bearing cap has a small squirt hole, oil
passes through the squirt hole and is thrown off as
the rod rotates. This oil throwoff lubricates the cam-
shaft lobes, distributor drive gear, cylinder walls, and
piston pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. Oil is provided to the cam-
shaft bearing through galleries. The front camshaft
bearing journal passes oil through the camshaft
sprocket to the timing chain. Oil drains back to the
oil pan under the number one main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components,
then passes down through the push rod guide holes
in the cylinder head past the valve tappet area, and
returns to the oil pan (Fig. 73).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Disconnect connector and remove oil pressure
sending unit.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 or equivalent. Start engine and record pres-
sure. (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct pressures.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.If the oil leak source is not pos-itively identified at this time, proceed with the air
leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(2) Remove the CCV valve from the cylinder head
cover. Cap or plug the CCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service informa-
tion procedures.
(5) If the leakage occurs at the rear oil seal area,
INSPECTION FOR REAR SEAL AREA LEAKS .
(6) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the CCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
WJENGINE - 4.0L 9 - 51
LUBRICATION (Continued)

(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 transmission oil cooling lines (if
equipped) and oxygen sensor wiring supports that
are attached to the oil pan studs.
(14) Remove the oil pan bolts and studs. Carefully
slide the oil pan and gasket to the rear. If equipped
with an oil level sensor, take care not to damage the
sensor.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Fabricate 4 alignment dowels from 1 1/2 x 1/4
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 78).
(3) Install two dowels in the timing case cover.
Install the other two dowels in the cylinder block
(Fig. 79).
(4) Apply MopartSilicone Rubber Adhesive Seal-
ant on cylinder block to rear main bearing cap cor-
ners and cylinder block to front cover joints (four
places) (Fig. 80).
(5) Slide the one-piece gasket over the dowels and
onto the block and timing case cover.
(6) 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.
(7) Install the 1/4 inch oil pan bolts. Tighten these
bolts to 9.5 N´m (84 in. lbs.) torque. Install the 5/16
inch oil pan bolts (Fig. 81). Tighten these bolts to 15
N´m (132 in. lbs.) torque.
(8) Remove the dowels. Install the remaining 1/4
inch oil pan bolts. Tighten these bolts to 9.5 N´m (84
in. lbs.) torque.
Fig. 78 Fabrication of Alignment Dowels
1 - 1/488ý 1 1/288BOLT
2 - DOWEL
3 - SLOT
Fig. 79 Position of Dowels in Cylinder Block
1 - DOWEL HOLES
2 - CYLINDER BLOCK
3 - 5/1688HOLES
4 - 5/1688HOLES
Fig. 80 Oil Pan Sealer Location
1 - SEALER LOCATIONS
Fig. 81 Position of 5/16 inch Oil Pan Bolts
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
WJENGINE - 4.0L 9 - 55
OIL PAN (Continued)