Jeep Wrangler/YJ 1987-1995 Repair Guide

Timing Gear Cover and Seal

Print

REMOVAL & INSTALLATION



2.5L Engine

See Figures 1 through 8



Click image to see an enlarged view

Fig. Fig. 1: Removing the front timing cover retaining bolts (water pump removed for clarity)



Click image to see an enlarged view

Fig. Fig. 2: Use a back-up wrench behind the alternator bracket to remove the front timing cover retaining bolt at this location



Click image to see an enlarged view

Fig. Fig. 3: Removing the front timing cover from the vehicle



Click image to see an enlarged view

Fig. Fig. 4: Carefully pry the seal from the cover without damaging the cover edge



Click image to see an enlarged view

Fig. Fig. 5: Seat the seal in the cover using an installation tool



Click image to see an enlarged view

Fig. Fig. 6: Timing cover centering tool installation



Click image to see an enlarged view

Fig. Fig. 7: Timing cover centering and seal installation tools

Special tools are needed for this job.

  1. Remove the drive belts and fan shroud.
  2.  
  3. Unscrew the vibration damper bolts and washer.
  4.  
  5. Using a puller, remove the vibration damper.
  6.  
  7. 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.
  8.  
  9. Disconnect the battery ground.
  10.  
  11. Remove the air conditioning compressor/alternator bracket assembly and lay it out of the way. DO NOT DISCONNECT THE REFRIGERANT LINES!
  12.  
  13. Unbolt the cover from the block and oil pan. Remove the cover and front seal.
  14.  
  15. Cut off the oil pan side gasket end tabs and oil pan front seal tabs.
  16.  
  17. Clean all gasket mating surfaces thoroughly.
  18.  
  19. Remove the seal from the cover.
  20.  

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.  
  13. Install the cover bolts. Tighten the cover-to-block bolts to 5 ft. lbs. (7 Nm) and the cover-to-pan bolts to 11 ft. lbs. (15 Nm).
  14.  
  15. 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.
  16.  
  17. Position the tool and seal over the end of the crankshaft and insert the Draw Screw J-9163-2 into the installation tool.
  18.  
  19. Tighten the nut until the tool just contacts the cover.
  20.  
  21. Remove the tools and apply a light film of engine oil on the vibration damper hub contact surface of the seal.
  22.  
  23. 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).
  24.  
  25. Install all other parts in reverse order of removal.
  26.  

4.0L Engine

See Figure 8



Click image to see an enlarged view

Fig. Fig. 8: Timing cover assembly-all engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belt(s), fan and fan shroud. If equipped, remove the accessory drive belt pulley.
  4.  
  5. Remove the vibration damper retaining bolt and washer. Remove the vibration damper using a suitable puller.
  6.  
  7. Remove the accessory drive brackets attached to the timing cover.
  8.  
  9. Remove the A/C compressor, if equipped, and alternator bracket from the cylinder head and move to one side.
  10.  
  11. Remove the oil pan-to-timing case cover bolts and the cover-to-cylinder block bolts.
  12.  
  13. Remove the timing case cover front seal and gasket from the engine.
  14.  
  15. Cut off the oil pan side gasket end tabs and oil pan front seal tabs flush with the front face of the cylinder block. Remove the gasket tabs.
  16.  
  17. Clean the timing case cover, oil pan and cylinder block gasket surfaces.
  18.  
  19. Remove the crankshaft seal oil seal from the cover by prying it out with a suitable tool.
  20.  

To install:
  1. Install a new seal in the timing cover using a suitable seal installation tool.
  2.  
  3. Apply sealer to both sides of the replacement cover gasket and position the gasket on the cylinder block. Cut the end tabs off the replacement oil pan gasket corresponding to those cut off the original gasket. Attach the end tabs to the oil pan with sealer.
  4.  
  5. Coat the front cover seal end tab recesses generously with sealer and position the seal on the timing cover.
  6.  
  7. Apply engine oil to the seal-oil pan contact surface, then position the cover on the cylinder block.
  8.  
  9. Insert timing case cover alignment tool J22248 or equivalent, in the crankshaft opening. Install the cover-to-cylinder block bolts and tighten them to 62 inch lbs. (7 Nm). Install and tighten the oil pan-to-cover bolts to 11 ft. lbs. (13 Nm).
  10.  
  11. Remove the cover alignment tool and position a replacement oil seal on the tool with the seal lip facing outward. Apply a light coat of sealer to the seal and a light coat of oil to the crankshaft. Install the seal on the timing cover.
  12.  
  13. Apply a light film of oil to the vibration damper hub seal contact surface. Install the vibration damper using a suitable installation tool.
  14.  

Do not hammer the damper into place as damage may result to the damper or engine.

  1. Install and tighten the crankshaft vibration damper bolt to 80 ft. lbs. (108 Nm).
  2.  
  3. If equipped, install the crankshaft pulley and tighten the bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Install the accessory brackets.
  6.  
  7. Install the fan and fan shroud.
  8.  
  9. Install the drive belt(s) and adjust to the proper tension.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  

4.2L Engine

COVER REMOVED
  1. Remove the drive belts, engine fan and hub assembly, the accessory pulley, and vibration damper.
  2.  
  3. Remove the oil pan to timing chain cover screws and the screws that attach the cover to the block.
  4.  
  5. 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.
  6.  
  7. Remove the timing chain cover and gasket from the engine.
  8.  

To install:
  1. 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.
  2.  
  3. Apply seal compound (Perfect Seal, or equivalent) to both sides of the replacement timing case cover gasket and position the gasket on cylinder block.
  4.  
  5. Cut the end tabs off the replacement oil pan gasket corresponding to the pieces cut off the original gasket. Cement these pieces on the oil pan.
  6.  
  7. Coat the oil pan seal end tabs generously with Permatex® No. 2 or equivalent, and position the seal on the timing case cover.
  8.  
  9. Position the timing case cover on the engine. Place Timing Case Cover Alignment Tool and Seal Installer J-22248 in the crankshaft opening of the cover.
  10.  
  11. Install the cover-to-block screws and oil pan-to-cover screws. Tighten the cover-to-block screws to 60 inch lbs. (7 Nm) and the oil pan-to-cover screws to 11 ft. lbs. (15 Nm).
  12.  
  13. Remove the cover aligning tool and position the replacement oil seal aligning tool in the case. Position the replacement oil seal on the tool with the seal lip facing outward. Apply a light film of Perfect Seal, or equivalent, on the outside diameter of the seal.
  14.  
  15. Insert the draw screw from Tool J-9163 into the seal installing tool. Tighten the nut against the tool until the tool contacts the cover.
  16.  
  17. Remove the tools and apply a light film of engine oil to the seal lip.
  18.  
  19. Install the vibration damper and tighten the retaining screw to 80 ft. lbs. (108 Nm).
  20.  
  21. Install the damper pulley. Tighten the capscrews to 20 ft. lbs. (27 Nm).
  22.  
  23. Install the engine fan and hub assembly.
  24.  
  25. Install the drive belt(s).
  26.  

COVER INSTALLED
  1. Remove the drive belts.
  2.  
  3. Remove the vibration damper pulley.
  4.  
  5. Remove the vibration damper.
  6.  
  7. Remove the oil seal with Tool J-9256.
  8.  
  9. Position the replacement oil seal on the Timing Case Cover Alignment Tool and Seal Installer J-22248 with the seal lip facing outward. Apply a light film of Perfect Seal, or equivalent, to the outside diameter of the seal.
  10.  
  11. Insert the draw screw from Tool J-9163 into the seal installing tool. Tighten the nut against the tool until the tool contacts the cover.
  12.  
  13. Remove the tools. Apply a light film of engine oil to the seal lip.
  14.  
  15. Install the vibration damper and tighten the retaining bolt to 80 ft. lbs. (108 Nm).
  16.  
  17. Install the damper pulley. Tighten the capscrews to 20 ft. lbs. (27 Nm).
  18.  
  19. Install the drive belt(s).
  20.  

 
label.common.footer.alt.autozoneLogo