Cherokee, Grand Cherokee, 1999-2005

Timing Chain Cover, Chain & Sprockets

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Removal & Installation



2.5L & 4.0L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Cooling fan and shroud
     
    Crankshaft damper
     
    Front crankshaft seal
     
    Accessory brackets
     
    Front cover
     
    Oil slinger
     

  4.  
  5. Rotate the crankshaft so that the timing marks are aligned.

    Click image to see an enlarged view

    Fig. Timing chain alignment marks-2.5L and 4.0L engines

  6.  
  7. Remove the timing chain and sprockets.
  8.  

To install:

  1. For 2.5L engines, turn the timing chain tensioner lever to the unlock (down) position. Pull the tensioner block toward the tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position.

    Click image to see an enlarged view

    Fig. Timing chain tensioner-2.5L engines

  2.  
  3. Install or connect the following:

    Timing chain and sprockets with the timing marks aligned. Torque the camshaft sprocket bolt to 80 ft. lbs. (108 Nm) for 2.5L engines or to 50 ft. lbs. (68 Nm) for 4.0L engines.
     

  4.  
  5. For 2.5L engines, release the timing chain tensioner.

    Oil slinger
     
    New front crankshaft seal to the front cover
     
    Front cover, using a new gasket
     
    Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening to center the front cover

    Click image to see an enlarged view

    Fig. Timing Case Cover Alignment and Seal Installation Tool 6139-2.5L and 4.0L engines

     

  6.  
  7. Torque the front cover bolts as follows:
    1. Step 1: Cover-to-block 1 / 4 inch bolts to 60 inch lbs. (7 Nm).
    2.  
    3. Step 2: Cover-to-block 5 / 16 inch bolts to 16 ft. lbs. (22 Nm).
    4.  
    5. Step 3: Oil pan-to-cover 1 / 4 inch bolts to 85 inch lbs. (9.5 Nm).
    6.  
    7. Step 4: Oil pan-to-cover 5 / 16 inch bolts to 11 ft. lbs. (15 Nm).
    8.  

  8.  
  9. Install or connect the following:

    Accessory brackets
     
    Crankshaft damper. Torque the bolt to 80 ft. lbs. (108 Nm).
     
    Cooling fan and shroud
     
    Accessory drive belt
     
    Negative battery cable
     

  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Drain cooling system.
  6.  
  7. Disconnect both heater hoses at timing cover.
  8.  
  9. Disconnect lower radiator hose at engine.
  10.  
  11. Remove crankshaft damper.
  12.  
  13. Remove accessory drive belt tensioner assembly.
  14.  
  15. Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover cylinder exhaust stroke) and the camshaft sprocket -V8- marks are at the 12 o-clock position.
  16.  
  17. Remove power steering pump.
  18.  
  19. Remove access plugs from left and right cylinder heads for access to chain guide fasteners.
  20.  
  21. Remove the oil fill housing to gain access to the right side tensioner arm fastener.
  22.  
  23. Remove the generator and A/C compressor.
    WARNING
    The 4.7L engine uses an RTV sealer instead of a gasket to seal the front cover to the engine block, from the factory. For service, Mopar® Grey Engine RTV sealant must be substituted.


    NOTE
    It is not necessary to remove the water pump for timing cover removal.

  24.  
  25. Remove the bolts holding the timing cover to engine block.
  26.  
  27. Remove cover.
  28.  
  29. Disconnect negative cable from battery.
  30.  
  31. Drain cooling system.
  32.  
  33. Remove right and left cylinder head covers.
  34.  
  35. Remove radiator fan.
  36.  
  37. Collapse and pin primary chain tensioner.
    WARNING
    Plate behind left secondary chain tensioner could fall into oil pan. Therefore, cover pan opening.

  38.  
  39. Remove secondary chain tensioners.
  40.  
  41. Remove camshaft position sensor from right cylinder head.
    WARNING
    Care should be taken not to damage camshaft target wheel. Do not hold target wheel while loosening or tightening camshaft sprocket. Do not place the target wheel near a magnetic source of any kind. A damaged or magnetized target wheel could cause a vehicle no start condition.


    WARNING
    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.

  42.  
  43. Remove left and right camshaft sprocket bolts.
  44.  
  45. While holding the left camshaft steel tube with adjustable pliers, remove the left camshaft sprocket. Slowly rotate the camshaft approximately 15 degrees clockwise to a neutral position.
  46.  
  47. While holding the right camshaft steel tube with adjustable pliers, remove the right camshaft sprocket. Slowly rotate the camshaft approximately 45 degrees counterclockwise to a neutral position.
  48.  
  49. Remove idler sprocket assembly bolt.
  50.  
  51. Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the primary and secondary chains.
  52.  
  53. Remove both pivoting tensioner arms and chain guides.
  54.  
  55. Remove chain tensioner.
  56.  

To install:

  1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin.
  2.  
  3. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 250 inch lbs. (28 Nm).
    WARNING
    Over-tightening the tensioner arm Torx® bolt can cause severe damage to the cylinder head. Tighten bolt to specified torque only.

  4.  
  5. Install right side chain tensioner arm. Apply Mopar® Lock N, Seal to Torx® bolt, tighten bolt to 150 inch lbs. (17 Nm).
    NOTE
    The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.

  6.  
  7. Install the left side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
    WARNING
    Over-tightening the tensioner arm can cause severe damage to the cylinder head. Tighten bolt to specified torque only.

  8.  
  9. Install left side chain tensioner arm. Apply Mopar® Lock N, Seal to bolt, tighten bolt to 150 inch lbs. (17 Nm).
  10.  
  11. Install the right side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
  12.  
  13. Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o-clock and 8 o-clock). Once the secondary timing chains are installed, position special tool 8515 to hold chains in place for installation.
  14.  
  15. Align primary chain double plated links with the timing mark at 12 o-clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o-clock on the crankshaft sprocket.
  16.  
  17. Lubricate idler shaft and bushings with clean engine oil.
  18.  
  19. Install all chains, crankshaft sprocket, and idler sprocket as an assembly. After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation.
    NOTE
    It will be necessary to slightly rotate camshafts for sprocket installation.

  20.  
  21. Align left camshaft sprocket -L- dot to plated link on chain.
  22.  
  23. Align right camshaft sprocket -R- dot to plated link on chain.
    WARNING
    Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over torque of bolt resulting in bolt failure.

  24.  
  25. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
  26.  
  27. Verify that all plated links are aligned with the marks on all sprockets and the -V8- marks on camshaft sprockets are at the 12 o-clock position.
    WARNING
    Ensure the plate between the left secondary chain tensioner and block is correctly installed.

  28.  
  29. Install both secondary chain tensioners. Tighten bolts to 250 inch lbs. (28 Nm).
    NOTE
    Left and right secondary chain tensioners are not common.

  30.  
  31. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 25 ft. lbs. (34 Nm).
  32.  
  33. Remove all locking pins from tensioners.
    WARNING
    After pulling locking pins out of each tensioner, do not manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.

  34.  
  35. Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left and right. camshaft sprocket bolts to 90 ft. lbs. (122 Nm).
  36.  
  37. Rotate engine two full revolutions. Verify timing marks are at the following locations:

    primary chain idler sprocket dot is at 12 o-clock
     
    primary chain crankshaft sprocket dot is at 6 o-clock
     
    secondary chain camshaft sprockets -V8- marks are at 12 o-clock
     

  38.  
  39. Lubricate all three chains with engine oil.
  40.  
  41. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within 0.10-0.25mm (0.004-0.010 in.). If not within specification, the idler gear and idler shaft must be replaced.
    WARNING
    Do not use oil based liquids to clean timing cover or block surfaces. Use only rubbing alcohol, along with plastic or wooden scrapers. Use no wire brushes or abrasive wheels or metal scrapers, or damage to surfaces could result.

  42.  
  43. Clean timing chain cover and block surface using rubbing alcohol.
    WARNING
    The 4.7L can use a special RTV sealer instead of a carrier gasket to seal the timing cover to the engine block, from the factory. For service repairs, Mopar® Grey Engine RTV must be used as a substitute, if RTV is present. If the front cover being used has no provisions for the water passage O-rings, then Mopar® Grey Engine RTV must be applied around the water passages.

  44.  
  45. Inspect the water passage O-rings, if equipped for any damage, and replace as necessary.
  46.  
  47. Apply Mopar® Grey Engine RTV sealer to the front cover following the path above, using a 3 to 4mm thick bead.
  48.  
  49. Install cover. Tighten flange head fasteners in sequence as shown in to 43 ft. lbs. (58 Nm).
  50.  
  51. Install the A/C compressor and generator.
  52.  
  53. Install crankshaft damper.
  54.  
  55. Install accessory drive belt tensioner assembly. Tighten fastener to 40 ft. lbs. (54 Nm).
  56.  
  57. Install lower radiator hose.
  58.  
  59. Install both heater hoses.
  60.  
  61. Install cylinder head covers.
    NOTE
    Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.

  62.  
  63. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon, then install into the right cylinder head and tighten to 60 ft. lbs. (81 Nm).
  64.  
  65. Install the oil fill housing.
  66.  
  67. Install access plug in left cylinder head.
  68.  
  69. Install power steering pump.
  70.  
  71. Install radiator fan.
  72.  
  73. Fill cooling system.
  74.  
  75. Connect negative cable to battery.

    Click image to see an enlarged view

    Fig. Crankshaft timing marks-4.7L engine



    Click image to see an enlarged view

    Fig. Camshaft positioning-4.7L engine



    Click image to see an enlarged view

    Fig. Cylinder head access plug locations-4.7L engine



    Click image to see an enlarged view

    Fig. Compress and lock the primary chain tensioner-4.7L engine



    Click image to see an enlarged view

    Fig. Secondary timing chain tensioner preparation-4.7L engine



    Click image to see an enlarged view

    Fig. Use the Timing Chain Locking tool to lock the timing chains on the idler gear-4.7L engine



    Click image to see an enlarged view

    Fig. Timing chain system and alignment marks-4.7L engine



    Click image to see an enlarged view

    Fig. Timing chain cover bolt torque sequence-4.7L engine

  76.  

5.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove air cleaner assembly.
  8.  
  9. Drain cooling system.
  10.  
  11. Remove accessory drive belt.
  12.  
  13. Remove fan and fan drive assembly.
  14.  
  15. Remove coolant bottle and washer bottle.
  16.  
  17. Remove fan shroud.
    NOTE
    It is not necessary to disconnect A/C lines or discharge refrigerant.

  18.  
  19. Remove A/C compressor and set aside.
  20.  
  21. Remove the generator.
  22.  
  23. Remove upper radiator hose.
  24.  
  25. Disconnect both heater hoses at timing cover.
  26.  
  27. Disconnect lower radiator hose at engine.
  28.  
  29. Remove accessory drive belt tensioner and both idler pulleys.
  30.  
  31. Remove crankshaft damper.
    NOTE
    Do not remove the hoses from the power steering pump.

  32.  
  33. Remove power steering pump and set aside.
  34.  
  35. Remove the dipstick support bolt.
  36.  
  37. Drain the engine oil.
  38.  
  39. Remove the oil pan and pick up tube.
    NOTE
    It is not necessary to remove water pump for timing cover removal.

  40.  
  41. Remove timing cover bolts and remove cover.
  42.  
  43. Verify that timing cover slide bushings are located in timing cover.
  44.  
  45. Reinstall the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown.
    WARNING
    The camshaft pin and the slot in the cam sprocket must be clocked at 12:00 (2). The crankshaft keyway must be clocked at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.



    Click image to see an enlarged view

    Fig. The camshaft pin and the slot in the cam sprocket must be clocked at 12:00 (2). The crankshaft keyway must be clocked at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00-5.7L Engine

  46.  
  47. Remove oil pump.

    Click image to see an enlarged view

    Fig. Retract tensioner shoe until hole in shoe lines up with hole in bracket. Slide a suitable pin into the holes-5.7L Engine

  48.  
  49. Retract tensioner shoe until hole in shoe lines up with hole in bracket.
  50.  
  51. Slide a suitable pin into the holes.
  52.  
  53. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
  54.  
  55. If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.
  56.  

To install:

  1. If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 250 inch lbs. (28 Nm).
  2.  
  3. Retract tensioner if required.
    WARNING
    The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links.


    WARNING
    The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.

  4.  
  5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores.
  6.  
  7. Place timing chain around both sprockets.
  8.  
  9. Lift sprockets and chain (keep sprockets tight against the chain in position as shown).
  10.  
  11. Slide both sprockets evenly over their respective shafts and check alignment of timing marks.
  12.  
  13. Install the camshaft bolt. Tighten the bolt to 90 ft. lbs. (122 Nm).
  14.  
  15. Remove tensioner pin. Again, verify alignment of timing marks.
  16.  
  17. Install the oil pump.
  18.  
  19. Install the oil pan and pick up.
  20.  
  21. Clean timing chain cover and block surface.
    NOTE
    Always install a new gasket on timing cover.

  22.  
  23. Verify that the slide bushings are installed in timing cover.
  24.  
  25. Install cover and new gasket. Tighten fasteners to 250 inch lbs. (28 Nm).
    NOTE
    The large lifting stud is torqued to 40 ft. lbs. (55 Nm).

  26.  
  27. Install the oil pan and pick up tube.
  28.  
  29. Install the A/C compressor.
  30.  
  31. Install the generator.
  32.  
  33. Install power steering pump.
  34.  
  35. Install the dipstick support bolt.
  36.  
  37. Install the thermostat housing.
  38.  
  39. Install crankshaft damper.
  40.  
  41. Install accessory drive belt tensioner assembly and both idler pulleys.
  42.  
  43. Install radiator lower hose.
  44.  
  45. Install both heater hoses.
  46.  
  47. Install radiator fan shroud.
  48.  
  49. Install the fan and fan drive assembly
  50.  
  51. Install the accessory drive belt.
  52.  
  53. Install the coolant bottle and washer bottle.
  54.  
  55. Install the upper radiator hose.
  56.  
  57. Install the air cleaner assembly.
  58.  
  59. Fill cooling system.
  60.  
  61. Refill engine oil.
  62.  
  63. Connect the battery negative cable.
  64.  
  65. Install the engine cover.
  66.  

 
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