Jeep Wagoneer/Commando/Cherokee 1984-1998

Timing Chain Cover and Seal

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2.5L Engine

See Figures 1, 2 and 3

  1. Disconnect the battery ground.
  2.  
  3. Remove the drive belts and fan shroud.
  4.  
  5. Unscrew the vibration damper bolts and washer.
  6.  



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Fig. Fig. 1: 2.5L timing cover assembly

  1. Using a puller, remove the vibration damper.
  2.  
  3. Remove the fan assembly. If the fan is equipped with a fan clutch DO NOT LAY IT DOWN! If you lay it down, the fluid will leak out of the clutch and irreversibly damage the fan.
  4.  
  5. Remove the air conditioning compressor/alternator bracket assembly and lay it out of the way. DO NOT DISCONNECT THE REFRIGERANT LINES!
  6.  
  7. Unbolt the cover from the block and oil pan. Remove the cover and front seal.
  8.  
  9. Cut off the oil pan side gasket end tabs and oil pan front seal tabs.
  10.  
  11. Clean all gasket mating surfaces thoroughly.
  12.  
  13. Remove the seal from the cover.
  14.  

To install:
  1. Apply sealer to both sides of the new case cover gasket and position it on the block.
  2.  
  3. Cut the end tabs off the new oil pan side gaskets corresponding to those cut off the original gasket and attach the tabs to the oil pan with gasket cement.
  4.  
  5. Coat the front cover seal end tab recesses generously with RTV sealant and position the side seal in the cover.
  6.  
  7. Apply engine oil to the seal-to-pan contact surface.
  8.  
  9. Position the cover on the block.
  10.  
  11. Insert alignment tool J-22248 into the crankshaft opening in the cover.
  12.  



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Fig. Fig. 2: Timing cover centering tool

  1. Install the cover bolts. Tighten the cover-to-block bolts to 5 ft. lbs. (7 Nm); the cover-to-pan bolts to 11 ft. lbs. (15 Nm).
  2.  
  3. Remove the alignment tool and position the new front seal on the tool with the seal lip facing outward. Apply a light film of sealer to the outside diameter of the seal. Lightly coat the crankshaft with clean engine oil.
  4.  
  5. Position the tool and seal over the end of the crankshaft and insert the Draw Screw J-9163-2 into the installation tool.
  6.  



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Fig. Fig. 3: Oil seal installation tool

  1. Tighten the nut until the tool just contacts the cover.
  2.  
  3. Remove the tools and apply a light film of engine oil on the vibration damper hub contact surface of the seal.
  4.  
  5. With the key inserted in the keyway in the crankshaft install the vibration damper, washer and bolt. Lubricate the bolt and tighten it to 108 ft. lbs. (146 Nm).
  6.  
  7. If equipped with a serpentine belt, tighten the pulley-to-damper bolts to 20 ft. lbs. (27 Nm). Install all other parts in reverse order of removal.
  8.  

2.8L Engine

See Figure 4

  1. Disconnect the battery ground.
  2.  
  3. Remove the drive belts.
  4.  
  5. Remove the fan shroud.
  6.  
  7. Remove the fan and pulley. If the fan is equipped with a fan clutch, DO NOT LAY IT ON ITS SIDE! If you do, the fluid will leak out and the fan clutch will have to be replaced.
  8.  
  9. Drain the cooling system.
  10.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air conditioning compressor and mounting bracket and position them out of the way. DO NOT DISCONNECT THE REFRIGERANT LINES!
  2.  
  3. Remove the water pump.
  4.  
  5. Remove the vibration damper retaining bolt and, using a puller, remove the damper.
  6.  

On some vehicles the outer ring (weight) of the harmonic balancer is bonded to the hub with rubber. The balancer must be removed with a puller which acts on the inner hub only. Pulling on the outer portion of the balancer will break the rubber bond or destroy the tuning of the torsional damper.

  1. Disconnect the lower radiator hose.
  2.  
  3. Unbolt and remove the cover. Pry out the seal.
  4.  

To install:
  1. Thoroughly remove all traces of gasket material from the mating surfaces.
  2.  



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Fig. Fig. 4: RTV sealer application for the 2.8L engine

  1. Position a new seal in the cover with the open end of the seal facing outward.
  2.  
  3. Apply a 3 / 32 in. (2.5mm) bead of RTV silicone gasket material to the mating surfaces of the cover and block. Place the cover on the block and install the bolts. Tighten the M8 x 1.25 bolts to 18 ft. lbs. (24 Nm); the M10 x 1.5 bolts to 30 ft. lbs. (41 Nm). Tighten the bolts within five minutes, as the sealer will begin to set.
  4.  
  5. Install all other parts in reverse order of removal.
  6.  

Breakage may occur if the balancer is hammered back onto the crankshaft. A press or special installation tool is necessary.

4.0L Engine

See Figures 5 and 6

  1. Remove the drive belts, engine fan and hub assembly, the accessory pulley and vibration damper.
  2.  
  3. Remove the air conditioning compressor and alternator bracket assembly and set it aside. Don't disconnect the refrigerant lines.
  4.  
  5. Remove the oil pan to timing chain cover screws and the screws that attach the cover to the block.
  6.  



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Fig. Fig. 5: Remove the bolts securing the cover to the block



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Fig. Fig. 6: Carefully remove the cover from the engine

  1. Raise the timing chain cover just high enough to detach the retaining nibs of the oil pan neoprene seal from the bottom side of the cover. This must be done to prevent pulling the seal end tabs away from the tongues of the oil pan gaskets, which would cause a leak.
  2.  
  3. Remove the timing chain cover and gasket from the engine. Make sure the timing chain tensioner spring and thrust pin do not fall out of the preload bolt.
  4.  
  5. Use a razor blade to cut off the oil pan seal end tabs flush with the front face of the cylinder block and remove the seal. Clean the timing chain cover, oil pan, and cylinder block surfaces.
  6.  
  7. Remove the crankshaft oil seal from the timing chain cover. Thoroughly clean the mating surfaces.
  8.  

To install:
  1. Apply RTV gasket material to both sides of the new gasket and position the gasket on the block.
  2.  
  3. Cut the end tabs off of the replacement oil pan side gaskets, corresponding to those cut off of the original gasket. Cement the end tabs to the oil pan.
  4.  
  5. Coat the front cover end tab recesses with a generous amount of RTV gasket sealant and position the seal on the timing case cover. Apply a coat of clean engine oil to the seal-to-pan contact surfaces.
  6.  
  7. Make sure the tension spring and thrust pin are in place in the preload bolt. Position the case cover on the block.
  8.  
  9. Place cover alignment tool (J-22248) in the crankshaft opening of the cover.
  10.  
  11. Install the cover-to-block bolts and the oil pan-to-cover bolts. Tighten the cover-to-block bolts to 62 inch Ibs. (7 Nm); the cover-to-pan bolts to 11 ft. lbs. (15 Nm).
  12.  
  13. Remove the alignment tool and position the seal on the tool with the lip facing outward.
  14.  
  15. Apply a light coat of sealer on the outside diameter of the seal.
  16.  
  17. Lightly coat the crankshaft with clean engine oil.
  18.  
  19. Position the tool and seal over the end of the crankshaft and insert a screw tool into the seal installation tool.
  20.  
  21. Tighten the nut against the tool until it contacts the cover.
  22.  
  23. Remove the tools and apply a light coating of engine oil on the vibration damper hub contact surface of the seal.
  24.  
  25. Install the damper.
  26.  
  27. Install all other parts in reverse order of removal. tighten the damper pulley bolts to 20 ft.lbs.
  28.  

5.2L and 5.9L Engines

See Figures 7, 8, 9 and 10

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Remove the cooling fan shroud and position it on the engine.
  10.  
  11. Remove the water pump.
  12.  
  13. Remove the power steering pump.
  14.  
  15. Remove the vibration damper using puller C-3688 or equivalent.
  16.  
  17. Disconnect the fuel lines.
  18.  
  19. Loosen the oil pan bolts and remove the front bolt at each side.
  20.  
  21. Remove the timing chain cover bolts. Remove the chain cover and gasket using extreme caution to avoid damaging the oil pan gasket.
  22.  



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Fig. Fig. 7: Carefully pry out the front cover oil seal

  1. Place a suitable tool behind the lips of the oil seal and pry the seal outward, being careful not to damage the crankshaft seal surface of the front cover.
  2.  

To install:
  1. Install a new timing chain cover gasket to the chain cover. Apply a small amount of Mopar silicone rubber adhesive sealant or equivalent, at the joint where the chain cover and oil pan gasket meet.
  2.  
  3. Install the timing chain cover taking care not to damage to oil pan. Finger tighten the cover bolts at this time.
  4.  



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Fig. Fig. 8: Proper placement of oil seal onto installation tool 6635



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Fig. Fig. 9: Installation of the seal and tool onto the crankshaft



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Fig. Fig. 10: Installing the front cover oil seal

  1. Position the smaller diameter of the oil seal on top of seal installation tool 6635. Seat the oil seal in the groove of the tool and then position both onto the crankshaft.
  2.  
  3. Tighten the 4 lower cover bolts to 10 ft. lbs. (13 Nm) to prevent the cover from tipping during seal installation.
  4.  
  5. Using the vibration damper bolt, tighten the bolt to draw the seal into position.
  6.  
  7. Loosen the 4 cover bolts to allow the timing chain cover to be realigned.
  8.  
  9. Tighten the timing chain cover bolts to 30 ft. lbs. (41 Nm) and oil pan bolts to 215 inch lbs. (24 Nm).
  10.  
  11. Remove the vibration damper bolt and the seal installation tool.
  12.  
  13. Install the vibration damper.
  14.  
  15. Connect the fuel lines.
  16.  
  17. Install the water pump.
  18.  
  19. Install the power steering pump.
  20.  
  21. Install the serpentine belt.
  22.  
  23. Install the cooling fan shroud.
  24.  
  25. Fill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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