Jeep Wrangler/YJ 1987-1995 Repair Guide

Timing Chain and Tensioner

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REMOVAL & INSTALLATION



2.5L Engine

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Crankshaft/camshaft sprocket alignment-2.5L engine



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Fig. Fig. 2: Sprockets and chain removal-2.5L engine



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Fig. Fig. 3: Loading timing chain tensioner-2.5L engine



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Fig. Fig. 4: Verify positioning of the crankshaft and camshaft sprockets-2.5L engine



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Fig. Fig. 5: Removing the crankshaft oil slinger-2.5L engine shown

  1. Remove the timing case cover.
  2.  
  3. Rotate the crankshaft so that the timing marks on the cam and crank sprockets align next to each other, as illustrated.
  4.  
  5. Remove the oil slinger from the crankshaft.
  6.  
  7. Remove the cam sprocket retaining bolt and remove the sprocket and chain. The crank sprocket may also be removed at this time. If the tensioner is to be removed, the oil pan must be removed first.
  8.  

To install:
  1. Prior to installation, turn the tensioner lever to the unlock (down) position.
  2.  
  3. Pull the tensioner block toward the tensioner to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position. The camshaft sprocket bolt should be torqued to 80 ft. lbs. (108 Nm).
  4.  
  5. Install the sprockets and chain together, as a unit. Make sure the timing marks are aligned.
  6.  
  7. To verify that the timing chain is correctly installed:
    1. Turn the crankshaft to place the camshaft timing mark at approximately the one o'clock position.
    2.  
    3. At this point, there should be a tooth on the crankshaft sprocket meshed with the chain at the three o'clock position.
    4.  
    5. Count the number of timing chain pins between the two timing marks on the right side (your right, facing the engine). There should be 20 pins.
    6.  

  8.  
  9. Install the oil pan, slinger and timing cover.
  10.  

4.0L Engine

See Figures 6 and 7



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Fig. Fig. 6: Crankshaft/camshaft sprocket alignment-4.0L engine



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Fig. Fig. 7: Verify crankshaft/camshaft sprocket installation-4.0L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belt(s), fan and fan shroud.
  4.  
  5. If equipped, remove the crankshaft pulley. Remove the vibration damper retaining bolt and washer.
  6.  
  7. Using a puller, remove the vibration damper.
  8.  
  9. Remove the timing case cover.
  10.  
  11. Rotate the crankshaft until the 0 timing mark on the crankshaft sprocket is closest to, and on a center line with, the timing mark on the camshaft sprocket.
  12.  
  13. Remove the oil slinger from the crankshaft.
  14.  
  15. Unfasten the camshaft retaining bolt, then remove the sprockets and chain as an assembly. If the timing chain tensioner is to be replaced, the oil pan must be removed.
  16.  

To install:
  1. 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.
  2.  
  3. Install the sprockets and timing chain. Ensure the timing marks on the sprockets are properly aligned.
  4.  
  5. Install the camshaft sprocket retaining bolt and washer and tighten to 80 ft. lbs. (108 Nm).
  6.  
  7. To verify correct alignment, turn the crankshaft to position the camshaft sprocket timing mark at the 1 o'clock position. This positions the crankshaft sprocket timing mark where the adjacent tooth meshes with the chain at the 3 o'clock position. Count the number of chain pins between the timing marks of both sprockets; there must be 15 pins.
  8.  
  9. Install the oil slinger, timing case cover and all other removed components in reverse order.
  10.  

4.2L Engine

See Figures 8 and 9



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Fig. Fig. 8: Crankshaft/camshaft sprocket alignment-4.2L engine



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Fig. Fig. 9: Verify crankshaft/camshaft sprocket installation-4.2L engine

  1. Remove the drive belts, engine fan and hub assembly, accessory pulley, vibration damper and timing chain cover.
  2.  
  3. Remove the oil seal from the timing chain cover.
  4.  
  5. Remove the camshaft sprocket retaining bolt and washer.
  6.  
  7. Rotate the crankshaft until the timing mark on the crankshaft sprocket is closest to, and in a center line with, the timing pointer of the camshaft sprocket.
  8.  
  9. Remove the crankshaft sprocket, camshaft sprocket and timing chain as an assembly. Disassemble the chain and sprockets.
  10.  

To install:
  1. Assemble the timing chain, crankshaft sprocket and camshaft sprocket with the timing marks aligned.
  2.  
  3. With the key in the keyway on the crankshaft, install the assembly on the crankshaft and camshaft.
  4.  
  5. Install the camshaft sprocket retaining bolt and washer and tighten to 80 ft. lbs. (108 Nm).
  6.  
  7. To verify correct alignment, turn the crankshaft to position the camshaft sprocket timing mark at the 1 o'clock position. This positions the crankshaft sprocket timing mark where the adjacent tooth meshes with the chain at the 3 o'clock position. Count the number of chain pins between the timing marks of both sprockets; there must be 15 pins.
  8.  
  9. Install the oil slinger, timing case cover and all other components removed in reverse order.
  10.  
  11. Install the timing chain cover and a new oil seal.
  12.  
  13. Install the vibration damper and tighten to 80 ft. lbs. (108 Nm), accessory pulley and tighten to 20 ft. lbs. (27 Nm), engine fan and hub assembly and drive belts. Tighten the belts to the proper tension.
  14.  

 
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