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Jeep Wrangler Sport 2010, Manual, Page: 130 / 211

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Jeep Wrangler Sport 2010 Manual Download Page 130

Fig. 161: CONNECTING ROD TO CYLINDER IDENTIFICATION
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable. 

2. Remove the cylinder heads. See 

Engine/Cylinder Head - Removal

. 

3. Remove the oil pan. See 

Engine/Lubrication/PAN, Oil - Removal

. 

4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons 

from cylinder block. 

Be sure to keep tops of pistons covered during this operation. Pistons and 

connecting rods must be removed from top of cylinder block. When removing piston and 
connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is 
centered in cylinder bore.

5. Inspect connecting rods and connecting rod caps for cylinder identification (1). Identify them if 

necessary. 

1 - PAINT MARK OR SCRIBE

NOTE:

Refer to the connecting rod Description before beginning repair. See 
Engine/Engine Block/ROD, Piston and Connecting - Description.

2010 Jeep Wrangler Sport

2010 ENGINE 3.8L - Service Information - Wrangler

viernes, 1 de octubre de 2021 05:18:31 p. m.

Page 130

© 2011 Mitchell Repair Information Company, LLC. 

Summary of Contents for Wrangler Sport 2010

Page 1: ...nder bank is numbered 1 3 and 5 The engine identification number is located on the rear of the cylinder block just below the cylinder head DIAGNOSIS AND TESTING INTRODUCTION Engine diagnosis is helpfu...

Page 2: ...INSPECTION PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 1 Test battery Charge or replace as necessary Refer to Electrical Battery System Diagnosis and Testing 2...

Page 3: ...restriction test Refer to Exhaust System Diagnosis and Testing Install new parts as necessary 9 Faulty ignition coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGI...

Page 4: ...and valves CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check engine oil level Inspect oil pump relief valve and spring 3 Thin or diluted oil 3 Change...

Page 5: ...ce 8 Oil pump suction tube loose 8 Remove oil pan and install new tube or clean if necessary 9 Oil pump cover warped or cracked 9 Install new oil pump 10 Excessive bearing clearance 10 Measure bearing...

Page 6: ...h an air hose with pressure gauge and regulator to the oil level indicator tube Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the suspected source Adjust the...

Page 7: ...very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged Th...

Page 8: ...ylinders 8 Compression should not be less than 689 kPa 100 psi and not vary more than 25 percent from cylinder to cylinder 9 If one or more cylinders have abnormally low compression pressures repeat t...

Page 9: ...pressure indications should be equal with no more than 25 leakage per cylinder FOR EXAMPLE At 552 kPa 80 psi input pressure a minimum of 414 kPa 60 psi should be maintained in the cylinder STANDARD PR...

Page 10: ...cially available gasket remover Plastic or wood scraper 4 Sealing surfaces must be free of grease or oil residue Clean surfaces with Mopar brake parts cleaner or equivalent MEASURING BEARING CLEARANCE...

Page 11: ...all readings taken Compare the clearance measurements to specifications found in the engine specifications table See Engine Specifications Plastigage generally is accompanied by two scales One scale i...

Page 12: ...rapidly cure when heat is applied MOPAR GASKET SEALANT is a slow drying permanently soft sealer This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolan...

Page 13: ...stall a new oil filter 11 Fill engine with specified amount of approved oil 12 Connect negative battery cable 13 Start engine and check for any leaks REPAIR OF DAMAGED OR WORN THREADS Damaged or worn...

Page 14: ...ing proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 in inside the lead in chamfer It is not necessary to wait for curing of the sealant The cooling s...

Page 15: ...2 Disconnect negative battery cable 3 Disconnect the Inlet Air Temp Sensor IAT 2 and remove air cleaner hose 1 and housing Fig 7 THROTTLE BODY 3 8L Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 20...

Page 16: ...VALVE LOCATION 3 8L Courtesy of CHRYSLER LLC 6 Disconnect the PCV hose 1 at the left cylinder head cover Fig 9 FRONT SPLASH SHIELD Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L S...

Page 17: ...the radiator 10 Disconnect the heater hoses and coolant reservoir hose Fig 10 GENERATOR ELECTRICAL CONNECTORS 3 8L Courtesy of CHRYSLER LLC 11 Disconnect the generator electrical connectors 1 2 2010 J...

Page 18: ...2 and the two engine wiring harness connectors Free the harness from the cover studs and set harness aside 13 Disconnect the purge solenoid harness connector Fig 12 EGR TUBE FLANGE Courtesy of CHRYSL...

Page 19: ...ation VALVE Exhaust Gas Recirculation EGR Removal Fig 13 GENERATOR MOUNTING 3 8L Courtesy of CHRYSLER LLC 16 Remove the drive belts 17 Remove the generator 3 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L...

Page 20: ...r head cover and oil level indicator tube Fig 15 MAP SENSOR 3 8L Courtesy of CHRYSLER LLC 20 Disconnect the knock sensor wiring harness connector 21 Remove the upper intake manifold 3 2010 Jeep Wrangl...

Page 21: ...eal all openings of hoses and compressor Fig 17 Suction Line to Compressor Courtesy of CHRYSLER LLC 24 Disconnect the A C suction line 2 from the compressor Cover and seal all openings of hoses and co...

Page 22: ...nect the coolant hose at the engine oil cooler 27 Remove the crankshaft sensor 2 CKP Fig 19 STARTER BATTERY CABLE 3 8L Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Inform...

Page 23: ...LLC 30 Remove the starter 1 31 Remove the flex plate inspection cover If equipped 32 Rotate the engine at the crankshaft pulley bolt and remove the torque converter bolts If equipped 2010 Jeep Wrangl...

Page 24: ...tesy of CHRYSLER LLC 34 Disconnect the right side oxygen sensors 1 2 35 Disconnect the exhaust pipes from the manifolds 36 Remove the left and right exhaust manifolds 2010 Jeep Wrangler Sport 2010 ENG...

Page 25: ...unting bolts 1 2 and cover If equipped 40 Support the transmission using a suitable jack 41 Connect engine lifting chain to engine and lift the engine using a suitable hoist 42 Lift the engine using a...

Page 26: ...ion 3 Tighten the engine mount thru bolts See Engine Engine Mounting INSULATOR Engine Mount Installation 4 Install the torque converter bolts If equipped Refer to Transmission and Transfer Case Automa...

Page 27: ...UNTING 3 8L Courtesy of CHRYSLER LLC 7 Install the starter 1 Refer to Electrical Starting STARTER Installation Fig 28 STARTER BATTERY CABLE 3 8L 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Infor...

Page 28: ...ORS RIGHT SIDE Courtesy of CHRYSLER LLC 10 Connect the knock sensor electrical connector 11 Install the left and right exhaust manifolds 12 Connect the exhaust system and connect the right side O2 sen...

Page 29: ...ct the in block heater if equipped 15 Connect the coolant hose at the engine oil cooler Fig 31 MAP SENSOR 3 8L Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wr...

Page 30: ...TUBE FLANGE Courtesy of CHRYSLER LLC 18 Install the EGR tube 1 Refer to Emissions Control Exhaust Gas Recirculation VALVE Exhaust Gas Recirculation EGR Installation 19 Connect the engine vacuum harnes...

Page 31: ...ssure MAP 2 and the engine wiring harness connectors Fig 34 Remove Install Discharge Line Courtesy of CHRYSLER LLC 22 Connect the A C discharge line 2 at the compressor Refer to Heating and Air Condit...

Page 32: ...COMPRESSOR A C Installation Fig 36 MOUNTING BOLTS Courtesy of CHRYSLER LLC 24 Install the power steering pump 1 Refer to Steering Pump Installation Fig 37 FUEL RAIL 3 8L Courtesy of CHRYSLER LLC 2010...

Page 33: ...ing GENERATOR Installation Fig 39 GENERATOR ELECTRICAL CONNECTORS 3 8L Courtesy of CHRYSLER LLC 27 Reconnect the generator wiring 1 2 Refer to Electrical Charging GENERATOR Installation 2010 Jeep Wran...

Page 34: ...coolant reservoir and heater hoses 30 Connect the throttle wiring harness ETC 3 Fig 41 PCV VALVE LOCATION 3 8L Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wr...

Page 35: ...AIR CLEANER Installation 34 Evacuate and recharge A C system Refer to Heating and Air Conditioning Plumbing Standard Procedure 35 Install new oil filter Fill engine crankcase with proper oil to correc...

Page 36: ...in system for example flywheel valvetrain camshaft and or crankshaft sensors or components Refer to DTC Based Diagnostics MODULE Powertrain Control PCM Standard Procedure DESCRIPTION SPECIFICATION Met...

Page 37: ...Main Bearing Journal Diameter 63 987 64 013 mm 2 5192 2 5202 in Journal Out of Round Max 0 005 mm 0 0002 in Journal Taper Max 0 003 mm 0 0001 in End Play 0 09 0 24 mm 0 0036 0 0095 in Wear Limit 0 38...

Page 38: ...Compression Rings 0 75 mm 0 030 in Wear Limit Oil Control Steel Rails 1 88 mm 0 074 in Ring Side Clearance Top Compression Ring 3 8L 0 030 0 069 mm 0 0012 0 0027 in Second Compression Ring 3 8L 0 041...

Page 39: ...pens 3 8L BBDC 46 Duration 3 8L 244 Intake Valve Timing Closes 3 8L ABDC 63 Opens 3 8L ATDC 1 Duration 3 8L 242 Valve Overlap 3 8L 17 DESCRIPTION SPECIFICATION Metric Standard Type Hydraulic Roller Ou...

Page 40: ...d Angle 44 5 45 Run Out Service Limits 0 0762 mm 0 003 in Width Intake and Exhaust 1 50 2 00 mm 0 057 0 078 in DESCRIPTION SPECIFICATION Metric Standard Guide Bore Diameter Std 6 975 7 00 mm 0 274 0 2...

Page 41: ...n DESCRIPTION SPECIFICATION Metric Standard At Curb Idle Speed Minimum with engine at operating temperature 34 47 kPa 5 psi At 3000 RPM 205 551 kPa 30 80 psi Oil Filter By Pass Valve Setting 62 103 kP...

Page 42: ...Bolts 12 105 Flex Plate to Crankshaft 88 65 Engine Mounting Refer to ENGINE MOUNTING Exhaust Manifold Bolts 23 200 Intake Manifold Lower Bolts 23 200 Intake Manifold Lower Gasket Retainer Bolts 12 10...

Page 43: ...y of CHRYSLER LLC Fig 46 INSTALLER CRANKSHAFT SPROCKET 8452 M8 Bolt 27 20 M10 Bolt 54 40 Water Pump Bolts 12 105 Water Pump Pulley Bolts 28 250 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Inform...

Page 44: ...g 48 CYLINDER INDICATOR C 119 Courtesy of CHRYSLER LLC Fig 49 COMPRESSOR VALVE SPRING 8453 Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viernes 1 de...

Page 45: ...ourtesy of CHRYSLER LLC Fig 52 REMOVER INSTALLER C 4129 A Courtesy of CHRYSLER LLC Fig 53 REMOVER SEAL 6341A Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wran...

Page 46: ...R INSTALLER C 3059A Courtesy of CHRYSLER LLC Fig 57 GAUGE PRESSURE C 3292A Courtesy of CHRYSLER LLC Fig 58 ADAPTER OIL PRESSURE 8406 Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L...

Page 47: ...CHEK KIT C 3685 A Courtesy of CHRYSLER LLC Fig 61 PRESSURE TRANSDUCER RPL CH7059 Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viernes 1 de octubre d...

Page 48: ...tesy of CHRYSLER LLC Fig 64 DECAY TOOL FUEL 8978 Courtesy of CHRYSLER LLC AIR INTAKE SYSTEM AIR CLEANER Removal REMOVAL 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viernes 1...

Page 49: ...le body 4 Remove the air cleaner cover bolts 5 Lift cover and pull toward the engine and remove cover tabs from air cleaner housing 6 Lift cover and remove the filter Installation INSTALLATION 2010 Je...

Page 50: ...r down over the element and lower housing and tighten the fasteners 4 Connect the air inlet tube to the throttle body and tighten the clamp 5 Connect the IAT sensor 2 6 Connect the CCV hose BODY AIR C...

Page 51: ...r 4 Remove the air inlet tube to throttle body 5 Remove the bolt for air cleaner housing at upper radiator cross member 6 Pull air box up and off over the single locating pin 7 Remove air box from veh...

Page 52: ...ss member 3 Install the air inlet tube to the throttle body and tighten clamp 4 Connect the IAT sensor 2 5 Connect the CCV hose to the air cleaner cover 6 Connect the negative battery cable CYLINDER H...

Page 53: ...ASKET A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket Possible indications of the cylinder head gasket leaking between adjacen...

Page 54: ...G SYSTEM TESTER METHOD Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the engine and observe the tester s pressure gauge If gauge pulsates with every power stroke of a cyl...

Page 55: ...gative cable from battery 3 Remove upper and lower intake manifolds WARNING INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY HANDLE WITH CARE 2010 Jeep Wrangler Sport 20...

Page 56: ...Removal 5 Remove the spark plugs from cylinder head 6 Remove the oil level indicator and tube Fig 72 ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1 INDICATOR 2 BOLT 3 TUBE 2010 Jeep Wrangler Sport...

Page 57: ...oper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Remove all gasket material from cylinder head and block See...

Page 58: ...tandard dimension less than 0 05 mm 0 002 inch Service Limit 0 2 mm 0 008 inch Grinding Limit Maximum of 0 2 mm 0 008 inch is permitted INSTALLATION INSTALLATION CAUTION 0 20 mm 0 008 in MAX is a comb...

Page 59: ...Check for Stretched Bolts Courtesy of CHRYSLER LLC 3 The cylinder head bolts should be examined BEFORE reuse If the threads are necked down the bolts must be replaced 4 Necking can be checked by hold...

Page 60: ...1 4 Turn Do not use a torque wrench for this step 6 Inspect and replace worn or bent push rods 7 Install the push rods 8 Install the rocker arm and shaft assemblies 2 See Engine Cylinder Head ROCKER...

Page 61: ...er and lower intake manifolds See Engine Manifolds MANIFOLD Intake Installation 13 Fill the cooling system Refer to Cooling Standard Procedure 14 Connect negative cable to battery COVER S CYLINDER HEA...

Page 62: ...D COVER 2 BOLT 3 SEAL SERVICED WITH BOLT 4 GASKET NOTE Due to the tight packaging near the cylinder head covers which makes spill clean up difficult a spill during an engine oil change may be misinter...

Page 63: ...er Fig 83 GENERATOR MOUNTING 3 8L Courtesy of CHRYSLER LLC 4 Remove the generator support bracket 1 2 5 Remove cylinder head cover bolts 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information W...

Page 64: ...tness Replace gasket as necessary 2 Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket 3 Install the cylinder head cover and bolts 4 Tighten cylind...

Page 65: ...ig 86 GENERATOR MOUNTING 3 8L Courtesy of CHRYSLER LLC 7 Install the generator support bracket 1 2 8 Connect spark plug wires to spark plugs 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Informati...

Page 66: ...s 3 Disconnect CCV hose from cylinder head cover 4 Remove cylinder head cover bolts 5 Remove cylinder head cover 1 and gasket 4 Installation INSTALLATION 1 CYLINDER HEAD COVER 2 BOLT 3 SEAL SERVICED W...

Page 67: ...gasket to cylinder cover by inserting the bolt assemblies through each bolt hole on the cover and gasket 4 Fig 89 CYLINDER HEAD COVER GASKET Courtesy of CHRYSLER LLC 1 CYLINDER HEAD COVER 2 BOLT 3 SE...

Page 68: ...e pushrods are positioned between the hydraulic lifter and the rocker arm Operation ROCKER ARMS The rocker arm pivots are on the rocker shaft Rocker arms are used to translate up and down motions prov...

Page 69: ...ved 3 Remove the rocker arms and shaft assembly 4 For rocker arm disassembly procedures see Engine Cylinder Head ROCKER ARM Valve Disassembly Disassembly DISASSEMBLY 1 ROCKER ARMS AND SHAFT ASSEMBLY 2...

Page 70: ...light rocking motion until the retainer disengages from shaft 1 ADJUSTABLE PLIERS 3 ROCKER ARM RETAINER 2 BILLETED ROCKER SHAFT BOLT CAUTION Do not attempt to drive the billeted bolt from the rocker s...

Page 71: ...r arms and shaft to the cylinder head See Engine Cylinder Head ROCKER ARM Valve Installation Installation 1 BOLT ROCKER SHAFT OIL FEED LONGER LENGTH 5 ROCKER ARM EXHAUST 2 SHAFT RETAINER SPACER 21 5 m...

Page 72: ...ND SHAFT ASSEMBLY 2 ROCKER SHAFT BOLTS CAUTION Ensure the longer shaft retaining bolt is installed in the proper location on the rocker shaft See Engine Cylinder Head ROCKER ARM Valve Assembly CAUTION...

Page 73: ...valve stem seal Installation INSTALLATION 1 Install the valve stem seal squarely over the valve guide using the valve stem as a guide Do not force the seal against top of the valve guide 2 Install th...

Page 74: ...to the left appearance And Type B may be identified by the clockwise spring spirals down and to the right appearance Both of the valve springs are a bee hive shaped design but have different specific...

Page 75: ...SPRING COMPRESSOR Courtesy of CHRYSLER LLC 1 With the cylinder head on a bench position Special Tool C 3422 D with 8464 Adapter on the valve and spring retainer 2 Compress the spring only enough to r...

Page 76: ...rom battery 2 Remove spark plug wires and all spark plugs 3 Remove cylinder head cover s See Engine Cylinder 8Head COVER S Cylinder Head Removal Fig 99 ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1...

Page 77: ...ves in place while servicing components 8 Locate the forcing screw and spring retainer adapter assembly over the spring requiring removal 9 Slowly turn the forcing screw clockwise compressing the valv...

Page 78: ...n torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Refer to Engine Spec...

Page 79: ...l Tool C 3422 D with 8464 Adapter compress the spring only enough to install the valve retainer locks Install valve retainer locks Fig 103 VALVE SPRING INSTALLED Courtesy of CHRYSLER LLC 1 SPECIAL TOO...

Page 80: ...ocedure on the remaining 5 cylinders using the firing sequence 1 2 3 4 5 6 Make sure piston in cylinder is at TDC on the valve spring that is being covered 3 Remove spark plug adapter tool 3 1 VALVE S...

Page 81: ...lated valve stems with four bead lock grooves The valve stem seals are made of Viton rubber Operation OPERATION The two valves per cylinder are opened using roller hydraulic lifters push rods and rock...

Page 82: ...Fig 107 Intake and Exhaust Valve Refacing Courtesy of CHRYSLER LLC 1 VALVE FACE WIDTH 2 VALVE FACE ANGLE 3 SEAT ANGLE 4 SEAT CONTACT AREA 1 VALVE FACE 2 VALVE MARGIN 2010 Jeep Wrangler Sport 2010 ENGI...

Page 83: ...e valve guide pilot be used for reseating stones A true and complete surface must be obtained 1 REFACING STONE MUST NOT CUT INTO CYLINDER HEAD 2 STONE 3 PILOT 4 SEAT CAUTION Remove metal from valve se...

Page 84: ...ce raise valve seat with a 65 degrees stone 4 When seat is properly positioned the width of intake and exhaust seats should be 1 50 2 00 mm 0 059 0 078 in Fig 110 VALVE INSTALLED HEIGHT Courtesy of CH...

Page 85: ...from top of spring seat to the bottom surface of spring retainer If height is greater than specifications install a 0 794 mm 0 0312 in spacer in head counterbore to bring spring height back within spe...

Page 86: ...lve guides Identify valves to insure installation in original location Cleaning CLEANING 1 Clean all valves thoroughly and discard burned warped and cracked valves Inspection INSPECTION VALVES 1 VALVE...

Page 87: ...ons see Engine Specifications VALVE GUIDES Fig 114 Measuring Valve Guide Wear Courtesy of CHRYSLER LLC 1 MARGIN 2 FACE 3 STEM 4 VALVE SPRING RETAINER LOCK GROOVES NOTE Valve stems are chrome plated an...

Page 88: ...arance specifications see Engine Specifications Installation INSTALLATION Fig 115 VALVE COMPONENTS Courtesy of CHRYSLER LLC 1 Coat valve stems with clean engine oil and insert them in cylinder head 2...

Page 89: ...springs See Engine Cylinder Head SPRING S Valve Installation ENGINE BLOCK DESCRIPTION DESCRIPTION The cylinder block is made of cast iron and is a deep skirt design STANDARD PROCEDURE CYLINDER BORE H...

Page 90: ...ing the hone up and down fast enough to get a cross hatch pattern When hone marks intersect at 40 60 degrees 2 the cross hatch angle is most satisfactory for proper seating of rings 4 A controlled hon...

Page 91: ...r with Tool C119 or equivalent See Engine Specifications If the cylinder walls are badly scuffed or scored the cylinder block should be replaced and new pistons and rings fitted Measure the cylinder b...

Page 92: ...one bank until complete Connecting rod bearings are available in the standard size and the following undersizes 0 025 mm 0 001 in and 0 250 mm 0 010 in Measure connecting rod journal for taper and ou...

Page 93: ...he rod cap to the specified torque Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared giving inaccurate results 5 Remove the bearing cap and compare the width of th...

Page 94: ...alves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine All bearing cap bolts removed during service procedures are to be cleaned...

Page 95: ...shim e g cardboard matchbook cover etc between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 N m 10 15 ft lbs a When checking 1 main bearing shim 2 main...

Page 96: ...ge 1 with the scale provided on the package Locate the band closest to the same width This band shows the amount of clearance in thousandths Differences in readings between the ends indicate the amoun...

Page 97: ...earing s with the appropriate size and if necessary have the crankshaft machined to next undersize Removal REMOVAL Fig 125 Main Bearing Cap Identification Courtesy of CHRYSLER LLC 1 Remove the oil pan...

Page 98: ...g Cap Identification 1 STRETCHED BOLT 2 THREADS ARE NOT STRAIGHT ON LINE 3 THREADS ARE STRAIGHT ON LINE 4 UNSTRETCHED BOLT NOTE One main bearing should be selectively fitted while all other main beari...

Page 99: ...Tighten the 2 Thrust Bearing cap bolts to 41 N m 1 4 Turn 30 ft lbs 1 4 Turn Remove the holding tool 9 Install oil pan See Engine Lubrication PAN Oil Installation 10 Fill engine crankcase with proper...

Page 100: ...to provide accurate valve timing and duration Removal REMOVAL Fig 129 HYDRAULIC LIFTERS Courtesy of CHRYSLER LLC 1 YOKE RETAINER 2 BOLT YOKE RETAINER 3 ALIGNING YOKE 4 HYDRAULIC LIFTER 2010 Jeep Wrang...

Page 101: ...Courtesy of CHRYSLER LLC 6 Remove camshaft thrust plate 2 7 Install a long bolt into front of camshaft to facilitate removal of the camshaft 8 Carefully remove the camshaft Inspection INSPECTION 1 OI...

Page 102: ...camshaft if out of limit Standard value is 0 0254 mm 0 001 in wear limit is 0 254 mm 0 010 in Installation INSTALLATION 1 UNWORN AREA 2 ACTUAL WEAR 3 BEARING JOURNAL 4 LOBE 5 WEAR ZONE NOTE If camsha...

Page 103: ...ll the hydraulic lifters with lubrication hole in the upward position See Engine Engine Block LIFTER S Hydraulic Installation 8 Install the timing chain cover See Engine Valve Timing COVER S Engine Ti...

Page 104: ...hoist 2 Remove the bolts retaining structural cover to transmission 1 2 3 Remove the bolts retaining structural cover to engine 4 Remove the structural cover Installation INSTALLATION 2010 Jeep Wrang...

Page 105: ...tighten bolts to 54 N m 40 ft lbs 6 Tighten the cover to transmission bolts to 54 N m 40 ft lbs CRANKSHAFT Description DESCRIPTION CAUTION The structural cover must be installed as described in the f...

Page 106: ...engine block Crankshaft end sealing is provided by front and rear rubber seals 1 MAIN BEARING CAP No 4 2 MAIN BEARING CAP No 3 3 MAIN BEARING CAP No 2 4 MAIN BEARING CAP BOLT 5 MAIN BEARING CAP No 1...

Page 107: ...shaft 2 Move crankshaft all the way to the rear of its travel 3 Zero the dial indicator 4 Move crankshaft all the way to the front and read the dial indicator See Engine Specifications for end play sp...

Page 108: ...and SPROCKETS Timing 7 Remove crankshaft rear oil seal and retainer See Engine Engine Block RETAINER Crankshaft Rear Oil Seal Removal 8 Rotate the crankshaft until connecting rod cap is accessible 9 P...

Page 109: ...T 5 MAIN BEARING CAP No 1 6 THRUST MAIN BEARING LOWER 7 THRUST MAIN BEARING UPPER 8 MAIN BEARING CAP CROSS BOLT 9 ENGINE BLOCK 10 MAIN BEARING UPPER 11 CRANKSHAFT 12 MAIN BEARING LOWER NOTE Install ne...

Page 110: ...RYSLER LLC 1 MAIN BEARING CAP No 4 2 MAIN BEARING CAP No 3 3 MAIN BEARING CAP No 2 4 MAIN BEARING CAP BOLT 5 MAIN BEARING CAP No 1 6 THRUST MAIN BEARING LOWER 7 THRUST MAIN BEARING UPPER 8 MAIN BEARIN...

Page 111: ...hat are stretched 10 MAIN BEARING UPPER 11 CRANKSHAFT 12 MAIN BEARING LOWER 1 STRETCHED BOLT 2 THREADS ARE NOT STRAIGHT ON LINE 3 THREADS ARE STRAIGHT ON LINE 4 UNSTRETCHED BOLT NOTE The main cap bolt...

Page 112: ...IN BEARING CAP BOLT 5 MAIN BEARING CAP No 1 6 THRUST MAIN BEARING LOWER 7 THRUST MAIN BEARING UPPER 8 MAIN BEARING CAP CROSS BOLT 9 ENGINE BLOCK 10 MAIN BEARING UPPER 11 CRANKSHAFT 12 MAIN BEARING LOW...

Page 113: ...See Engine Lubrication PAN Oil Installation 13 Install the engine assembly See Engine Installation DAMPER VIBRATION Removal REMOVAL Fig 143 VIBRATION DAMPER REMOVAL Courtesy of CHRYSLER LLC 1 Disconne...

Page 114: ...vibration damper bolt Torque bolt to 54 N m 40 ft lbs 6 Install the accessory drive belt Refer to Cooling Accessory Drive BELT Serpentine Installation 7 Connect negative cable to battery FLEXPLATE Re...

Page 115: ...3 Remove the flex plate 1 Installation INSTALLATION Fig 146 FLEX PLATE Courtesy of CHRYSLER LLC 1 FLEX PLATE 2 BOLT QTY 8 3 BACKING PLATE 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information...

Page 116: ...ription DESCRIPTION 1 FLEX PLATE 2 BOLT QTY 8 3 BACKING PLATE NOTE The Cam Crank Variation Relearn procedure must be performed anytime there has been a repair replacement made to a powertrain system f...

Page 117: ...tained by machined flats on lifter body Lifters are fitted in pairs into six aligning yokes The aligning yokes 3 are secured by a yoke retainer 1 Diagnosis and Testing HYDRAULIC LIFTERS HYDRAULIC LIFT...

Page 118: ...ould be operated at fast idle to allow all of the air inside of the lifters to be bled out VALVE TRAIN NOISE To determine source of valve train noise operate engine at idle with cylinder head covers r...

Page 119: ...hydraulic lifters If lifters are to be reused identify each lifter to ensure installation in original location Installation INSTALLATION 1 YOKE RETAINER 2 BOLT YOKE RETAINER 3 ALIGNING YOKE 4 HYDRAULI...

Page 120: ...brication hole facing upward towards middle of block Install lifters in original positions if reused NOTE Position the lifter in bore with the lubrication hole facing upward 2010 Jeep Wrangler Sport 2...

Page 121: ...normal operating temperature RETAINER CRANKSHAFT REAR OIL SEAL 1 YOKE RETAINER 2 BOLT YOKE RETAINER 3 ALIGNING YOKE 4 HYDRAULIC LIFTER CAUTION To prevent damage to valve mechanism engine must not be r...

Page 122: ...ove oil seal retainer bolts 1 4 Remove oil seal retainer 2 5 Clean engine block and retainer of oil and gasket material Make sure surfaces are clean and free of oil Installation INSTALLATION NOTE Any...

Page 123: ...Install the five rear crankshaft oil seal retainer fasteners Do not tighten at this time 7 Remove and discard the plastic installation sleeve 1 8 Tighten the five rear crankshaft oil seal retainer fas...

Page 124: ...ing gap with a feeler gauge 1 For clearance specification see Engine Specifications Fig 154 Piston Ring Side Clearance Courtesy of CHRYSLER LLC 2 Check piston ring to groove side clearance 1 For clear...

Page 125: ...der Installation INSTALLATION Fig 155 Piston Ring Installation Courtesy of CHRYSLER LLC 1 Install rings with manufacturers I D mark if present facing up to the top of the piston 1 NO 1 PISTON RING 2 N...

Page 126: ...Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring expander 3 Install lower side rail first and then the upper 1 side rail 4 Install No...

Page 127: ...e FITTING CONNECTING RODS Fig 158 Checking Cylinder Head Bolts Courtesy of CHRYSLER LLC 1 SIDE RAIL UPPER 2 NO 1 RING GAP 3 PISTON PIN 4 SIDE RAIL LOWER 5 NO 2 RING GAP AND SPACER EXPANDER GAP CAUTION...

Page 128: ...see Engine Engine Block BEARING S Connecting Rod Standard Procedure Fit all connecting rods on one bank until complete 1 STRETCHED BOLT 2 THREADS ARE NOT STRAIGHT ON LINE 3 THREADS ARE STRAIGHT ON LI...

Page 129: ...learance Refer to Engine Specifications See Engine Specifications FITTING PISTONS The piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin Cylinde...

Page 130: ...stons and connecting rods must be removed from top of cylinder block When removing piston and connecting rod assemblies from the engine rotate crankshaft so that each connecting rod is centered in cyl...

Page 131: ...embly 4 out of the cylinder bore 8 After removal install bearing cap on the mating rod Installation INSTALLATION 1 F TOWARD FRONT OF ENGINE 2 RING COMPRESSOR 3 SPECIAL TOOL 8189 4 OIL SQUIRT HOLE NOTE...

Page 132: ...ring rail gap 1 4 1 SIDE RAIL UPPER 2 NO 1 RING GAP 3 PISTON PIN 4 SIDE RAIL LOWER 5 NO 2 RING GAP AND SPACER EXPANDER GAP NOTE Refer to the connecting rod Description before beginning repair See Eng...

Page 133: ...f rings does not change during this operation 3 Position upper bearing onto connecting rod Lubricate bearing with oil 4 Install Guide Pins 8189 3 on the connecting rod 1 F TOWARD FRONT OF ENGINE 2 RIN...

Page 134: ...row 1 on top of the piston Install piston with this mark positioned to front of engine on both cylinder banks 1 ARROW FACES FRONT OF ENGINE 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Informatio...

Page 135: ...d oil squirt hole 2 faces the major thrust right side of the engine block 1 1 MAJOR THRUST SIDE OF PISTON 2 OIL SQUIRT HOLE 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viern...

Page 136: ...the appropriate connecting rod cap 9 Install the connecting rod cap bolts following this three step torque plus angle method Step 1 Tighten both bolts to 7 N m 5 ft lbs Step 2 Tighten both bolts to 2...

Page 137: ...of CHRYSLER LLC 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to Cooling Accessory Drive BELT Serpentine Removal 3 Remove crankshaft damper See Engine Engine Block DAMPE...

Page 138: ...CRANKSHAFT FRONT SEAL INSTALLATION Courtesy of CHRYSLER LLC 1 Position Special Tool C 4992 2 Guide 3 on the crankshaft nose 1 SEAL 2 SPECIAL TOOL 6341A 1 SPECIAL TOOL C 4992 1 2 SEAL 3 SPECIAL TOOL C...

Page 139: ...gine oil pan 4 Remove the cylinder block to insulator mount bolts and the nut from the engine insulator mount through bolt 5 Using the jack raise the engine high enough to remove the engine insulator...

Page 140: ...nuts holding support cushion to transmission support bracket 5 Remove the support cushion 2 6 Remove bolts holding transmission support bracket to transmission 7 Remove the transmission support brack...

Page 141: ...g support cushion to transmission support bracket Remove the support cushion 2 5 Remove the bolts holding the transmission support bracket to transmission 6 Remove the transmission support bracket Ins...

Page 142: ...upport 4 Lower the vehicle 5 Connect negative cable to battery 6 Position the transmission mount bracket to the transmission and install the bolts 7 Tighten the bolts to 54 N m 40 ft lbs torque 8 Posi...

Page 143: ...he transmission and install the bolts Tighten the bolts to 54 N m 40 ft lbs torque 7 Position the support cushion 2 to the transmission mount bracket and install nuts Tighten the nuts to 41 N m 30 ft...

Page 144: ...sure to the main and rod bearings camshaft bearings Passages in the cylinder block feed oil to the hydraulic lifters and rocker shaft brackets which feeds the rocker arm pivots DIAGNOSIS AND TESTING E...

Page 145: ...l Pressure Switch Courtesy of CHRYSLER LLC 1 Using suitable oil filter wrench turn filter 2 counterclockwise to remove from oil filter adapter Properly discard used oil filter Installation INSTALLATIO...

Page 146: ...oil 3 Install new filter 2 until gasket contacts base Tighten filter 1 turn or 20 N m 15 ft lbs Use filter wrench if necessary 4 Start engine and check for leaks OIL Standard Procedure ENGINE OIL AND...

Page 147: ...ll new oil filter 2 7 Lower vehicle and fill crankcase with specified type and amount of engine oil 8 Install oil fill cap WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED...

Page 148: ...r below the ADD mark on the indicator PAN OIL Removal REMOVAL 1 Disconnect negative cable from battery and remove engine oil level indicator tube 2 Remove engine oil level indicator tube Fig 179 3 8L...

Page 149: ...81 Upper Oil Pan To Engine Block Bolts Courtesy of CHRYSLER LLC 5 Remove the oil pan fasteners 1 oil pan and gasket NOTE Do not remove the lower oil pan bolts Only remove the upper oil pan to engine b...

Page 150: ...distortion Straighten flange if necessary 3 Inspect condition of oil screen and pick up tube clean or replace as necessary Installation INSTALLATION Fig 182 Oil Pan Sealing Courtesy of CHRYSLER LLC 1...

Page 151: ...ER Courtesy of CHRYSLER LLC 4 Install the structural cover and tighten fasteners 1 2 See Engine Engine Block COVER Structural Dust Installation 5 Lower vehicle and install oil level indicator 2010 Jee...

Page 152: ...ect negative cable to battery PUMP ENGINE OIL Description DESCRIPTION The oil pump is located in the timing chain cover It is driven by the crankshaft Removal REMOVAL 2010 Jeep Wrangler Sport 2010 ENG...

Page 153: ...assemble oil pump from timing chain cover 4 Clean and Inspect oil pump components Disassembly DISASSEMBLY 1 CHAIN CASE COVER 2 OIL PUMP INNER ROTOR 3 SCREW 4 OIL PUMP COVER 5 OIL PUMP OUTER ROTOR 2010...

Page 154: ...and inspect oil pump components Cleaning CLEANING 1 Clean all parts thoroughly in a suitable solvent Inspection INSPECTION 1 TIMING CHAIN COVER 2 SCREWS 3 INNER ROTOR 4 OUTER ROTOR 5 COVER 2010 Jeep...

Page 155: ...nd straight edge cover should be replaced Fig 189 Measuring Outer Rotor Thickness Courtesy of CHRYSLER LLC 3 Measure thickness and diameter of outer rotor If outer rotor thickness measures 7 64 mm 0 3...

Page 156: ...outer rotor into chain case cover Press rotor to one side with fingers and measure clearance between rotor and chain case cover If measurement is 0 39 mm 0 015 in or more replace chain case cover only...

Page 157: ...CHRYSLER LLC 7 Place a straightedge across the face of the chain case cover between bolt holes If a feeler gauge of 0 10 mm 0 004 in or more can be inserted between rotors and the straightedge replac...

Page 158: ...specifications 11 If oil pressure is low and pump is within specifications inspect for worn engine bearings or other reasons for oil pressure loss Assembly ASSEMBLY 1 Assemble pump using new parts as...

Page 159: ...for the instrument cluster low oil pressure indicator light The switch receives oil pressure input from the engine main oil gallery When engine oil pressure is greater than 27 5 kPa 4 psi the switch...

Page 160: ...e on hoist 2 Disconnect electrical connector from switch 3 Remove oil pressure switch 1 Installation INSTALLATION 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viernes 1 de oc...

Page 161: ...ect electrical connector to switch 3 Lower the vehicle 4 Start engine and check for leaks 5 Check engine oil level Adjust as necessary VALVE OIL PRESSURE RELIEF Removal REMOVAL 2010 Jeep Wrangler Spor...

Page 162: ...ig 198 Insert a self threading sheet metal screw into the cap 3 Using suitable pliers remove cap and discard 4 Remove spring and relief valve See Fig 198 Installation INSTALLATION 1 SPRING 2 RELIEF VA...

Page 163: ...rface 5 Install oil pan 6 Fill crankcase with proper oil to correct level MANIFOLDS MANIFOLD EXHAUST LEFT Removal REMOVAL 1 SPRING 2 RELIEF VALVE 3 RETAINER CAP NOTE Always use a new relief valve Do n...

Page 164: ...emove the fresh air hose 1 3 Disconnect left cylinder bank spark plug wires Fig 201 O2 SENSORS LEFT SIDE Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler...

Page 165: ...ds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge Manifold surface flatness limits shoul...

Page 166: ...ghten heat shield attaching nut 3 to 12 N m 105 in lbs Fig 203 O2 SENSORS LEFT SIDE Courtesy of CHRYSLER LLC 5 Attach exhaust pipe to exhaust manifold and tighten bolts to 41 N m 30 ft lbs 6 Connect t...

Page 167: ...he exhaust pipe at the exhaust manifold 3 Remove the air cleaner hose 1 and housing Fig 205 O2 SENSORS RIGHT SIDE Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information...

Page 168: ...exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge Manifold surface flatn...

Page 169: ...AT Sensor Courtesy of CHRYSLER LLC 5 Connect the IAC TPS and the EVAP hose to the throttle body 6 Attach exhaust pipe to exhaust manifold 7 Install the air cleaner housing and hose 1 8 Connect battery...

Page 170: ...oulder area provides sufficient stock to repair Also if the special screws that attach the MAP sensor power steering reservoir and the EGR tube become stripped an oversized screw is available to repai...

Page 171: ...ue tightening torque specification from the original screw Refer to the following chart for specification INTAKE MANIFOLD VACUUM PORT REPAIR DESCRIPTION TORQUE STRIP OUT REPAIR SCREWS ONLY MAP Sensor...

Page 172: ...ILL BIT 7 16 BRAKE BOOSTER PORT 2 DRILL BIT 11 32 LDP SPEED CONTROL PORT 3 INTAKE MANIFOLD NOTE While performing this procedure avoid getting the manifold material residue into the plenum chamber PART...

Page 173: ...rt 4 Apply Mopar Thread Sealant to threads of repair port s 5 Install repair port s Do not over torque repair port s Removal UPPER INTAKE MANIFOLD Fig 210 Hose Assembly IAT Sensor Courtesy of CHRYSLER...

Page 174: ...ttle body Fig 212 EGR TUBE FLANGE Courtesy of CHRYSLER LLC 6 Remove the EGR tube 1 Refer to Emissions Control Exhaust Gas Recirculation TUBE Exhaust Gas Recirculation EGR Removal 2010 Jeep Wrangler Sp...

Page 175: ...nifold 3 Fig 214 View of Power Brake Booster Hose Intake Manifold Courtesy of CHRYSLER LLC 8 Disconnect the power brake booster hose 1 at the rear of the intake manifold 2 and position aside 2010 Jeep...

Page 176: ...urtesy of CHRYSLER LLC 10 Remove the upper intake manifold bolts and remove the manifold 11 Cover the lower intake manifold ports with a suitable cover while the upper manifold is removed 2010 Jeep Wr...

Page 177: ...7 INTAKE TORQUE SEQUENCE 3 8L Courtesy of CHRYSLER LLC 1 Clean the gasket surfaces and remove the covering from the lower intake manifold ports 2 Inspect the intake manifold gasket condition gaskets c...

Page 178: ...s in the sequence shown in illustration to 12 N m 105 in lbs Fig 218 PCV VALVE LOCATION 3 8L Courtesy of CHRYSLER LLC 7 Connect the PCV hose 1 to the upper intake manifold Fig 219 View of Power Brake...

Page 179: ...nsor 1 at the rear of the intake manifold 3 by pushing down on the MAP sensor while rotating clockwise about 1 4 turn 10 Connect the MAP sensor electrical connector 2 Fig 221 EGR TUBE FLANGE 2010 Jeep...

Page 180: ...ttle body electrical connector 3 CAUTION The special screws used for attaching the EGR tube to the manifold must be installed slowly using hand tools only This requirement is to prevent the melting of...

Page 181: ...temperature IAT sensor electrical connector 2 16 Connect the negative battery cable and tighten nut to 5 N m 45 in lbs MANIFOLD INTAKE LOWER Removal LOWER INTAKE MANIFOLD 2010 Jeep Wrangler Sport 201...

Page 182: ...ard Procedure 2 Drain the cooling system 3 Remove the upper intake manifold See Engine Manifolds MANIFOLD Intake Removal Fig 225 FUEL RAIL 3 8L Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 E...

Page 183: ...RAIL 3 8L Courtesy of CHRYSLER LLC 7 Disconnect the fuel injector wire harness 8 Remove the fuel injectors and rail assembly 3 Refer to Fuel System Fuel Delivery RAIL Fuel Removal 9 Remove radiator up...

Page 184: ...ection Clogged water passages in end cross overs if equipped Check for cylinder head mounting surface distortion using a straightedge and thickness gauge See Engine Cylinder Head Inspection Installati...

Page 185: ...MANIFOLD TIGHTENING SEQUENCE Courtesy of CHRYSLER LLC 3 Install lower intake manifold Install the bolts and torque to 1 N m 10 in lbs Then torque bolts to 22 N m 200 in lbs in sequence shown in illust...

Page 186: ...y RAIL Fuel Installation 5 Connect fuel injector electrical harness Fig 231 FUEL RAIL 3 8L Courtesy of CHRYSLER LLC 6 Connect the engine coolant temperature sensor 2010 Jeep Wrangler Sport 2010 ENGINE...

Page 187: ...RIFICATION 1 Remove front cylinder head cover and all 6 spark plugs 2 Rotate engine until the 2 piston is at TDC of the compression stroke 3 Install a degree wheel on the crankshaft pulley 4 With prop...

Page 188: ...that any movement of chain may be measured 2 Position a torque wrench and socket on the camshaft sprocket attaching bolt Apply force in the direction of crankshaft rotation to take up slack to the fo...

Page 189: ...41 N m 30 ft lb with cylinder heads installed 20 N m 15 ft lb with cylinder heads removed 5 Measure amount of sprocket chain movement 6 Install a new timing chain and sprockets if movement exceeds 3...

Page 190: ...er See Engine Valve Timing COVER S Engine Timing Removal 1 7 BOLT M8 x 1 25 x 80 4 BOLT M10 x 1 5 x 85 2 BOLT M10 x 1 5 x 85 5 BOLT M8 x 1 25 x 80 3 BOLT M8 x 1 25 x 80 6 BOLT M10 x 1 5 x 85 2010 Jeep...

Page 191: ...ching bolt 5 Remove the timing chain with camshaft sprocket 6 Remove the crankshaft sprocket CRANKSHAFT SPROCKET 1 CAMSHAFT SPROCKET TIMING MARK DOT 2 PLATED LINK 3 CRANKSHAFT SPROCKET TIMING MARK DOT...

Page 192: ...while holding the crankshaft from turning Installation CRANKSHAFT SPROCKET 1 SPECIAL TOOL 5048 2 SPECIAL TOOL 8452 3 SPECIAL TOOL 8450 4 CRANKSHAFT SPROCKET 5 SPECIAL TOOL 8539 NOTE Be careful not to...

Page 193: ...haft 3 Install the timing chain See Engine Valve Timing CHAIN and SPROCKETS Timing Installation TIMING CHAIN AND CAMSHAFT SPROCKET 1 SPECIAL TOOL 8452 2 SPECIAL TOOL 8452 3 CRANKSHAFT SPROCKET 4 THRUS...

Page 194: ...sprocket into position 4 Use a straight edge to check alignment of timing marks 4 5 Install the camshaft sprocket bolt and washer Tighten the bolt to 54 N m 40 ft lbs 6 Rotate the crankshaft two revol...

Page 195: ...NG CHAIN COVER NOTE The Cam Crank Variation Relearn procedure must be performed anytime there has been a repair replacement made to a powertrain system for example flywheel valvetrain camshaft and or...

Page 196: ...Remove the air cleaner hose 1 and housing assembly See Engine Air Intake System BODY Air Cleaner Removal Fig 242 ACCESSORY DRIVE BELT ROUTING 3 8L Courtesy of CHRYSLER LLC 1 IDLER PULLEY 2 GENERATOR...

Page 197: ...he water pump pulley bolts Rotate the pulley 2 until the openings in the pulley align with the water pump drive hub spokes 1 and remove the pulley 2 3 A C COMPRESSOR 4 WATER PUMP PULLEY 5 CRANKSHAFT P...

Page 198: ...YSLER LLC 8 Raise and support the vehicle on a hoist Refer to Vehicle Quick Reference Hoisting Standard Procedure 9 Drain the engine oil and remove the oil filter 2 See Engine Lubrication OIL Standard...

Page 199: ...the oil level indicator 1 and tube 2 Fig 247 Upper Oil Pan To Engine Block Bolts Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Service Information Wrangler viernes 1 de octubre de...

Page 200: ...SLER LLC 12 Disconnect the lower radiator hose 13 Disconnect the heater hose 14 Disconnect the oil pressure switch 1 Fig 249 MOUNTING BOLTS Courtesy of CHRYSLER LLC 2010 Jeep Wrangler Sport 2010 ENGIN...

Page 201: ...REMOVAL Courtesy of CHRYSLER LLC 17 Remove the crankshaft vibration damper bolt 18 Place Crankshaft Insert 8450 2 into the crankshaft nose 19 Position Puller 1023 1 on the damper Turn the puller forci...

Page 202: ...mshaft Position Removal Fig 253 TIMING COVER BOLT LOCATION Courtesy of CHRYSLER LLC 1 7 BOLT M8 x 1 25 x 80 4 BOLT M10 x 1 5 x 85 2 BOLT M10 x 1 5 x 85 5 BOLT M8 x 1 25 x 80 3 BOLT M8 x 1 25 x 80 6 BO...

Page 203: ...nkshaft so that the oil pump drive flats are in the vertical position 4 Position the oil pump inner rotor so that the mating flats are in the same position as the crankshaft drive flats 1 7 BOLT M8 x...

Page 204: ...nd support the vehicle on a hoist Refer to Vehicle Quick Reference Hoisting Standard Procedure 8 Install the oil pan and structural cover See Engine Lubrication PAN Oil Installation severe damage may...

Page 205: ...tallation Fig 257 CRANKSHAFT DAMPER Courtesy of CHRYSLER LLC 1 SPECIAL TOOL C 4992 1 2 SEAL 3 SPECIAL TOOL C 4992 2 4 CRANKSHAFT 1 FORCING SCREW NUT FROM SPECIAL TOOL 8452 2 VIBRATION DAMPER 2010 Jeep...

Page 206: ...h Courtesy of CHRYSLER LLC 12 Connect the oil pressure switch 1 13 Connect the lower radiator hose 14 Connect the heater hose 15 Install a new oil filter 2 See Engine Lubrication FILTER Engine Oil Ins...

Page 207: ...llation Fig 260 A C COMPRESSOR MOUNTING BOLTS Courtesy of CHRYSLER LLC 17 Install the A C compressor 2 to the engine with three bolts 1 3 and 4 Tighten the bolts to 28 N m 21 ft lbs using the followin...

Page 208: ...he front of the compressor The bolt 3 at the rear of the compressor 18 Install the oil level indicator tube 3 and indicator 1 Tighten the bolt 2 to 20 N m 15 ft lbs 2010 Jeep Wrangler Sport 2010 ENGIN...

Page 209: ...TOR Installation Fig 263 MOUNTING BOLTS Courtesy of CHRYSLER LLC 20 Install the power steering pump 1 Tighten pump mounting bolts 2 to 26 N m 19 ft lbs 2010 Jeep Wrangler Sport 2010 ENGINE 3 8L Servic...

Page 210: ...SORY DRIVE BELT ROUTING 3 8L Courtesy of CHRYSLER LLC 1 IDLER PULLEY 2 GENERATOR PULLEY 3 A C COMPRESSOR 4 WATER PUMP PULLEY 5 CRANKSHAFT PULLEY 6 ACCESSORY DRIVE BELT TENSIONER 7 P S PUMP PULLEY 8 AC...

Page 211: ...ystem BODY Air Cleaner Installation 24 Fill the engine crankcase with the proper oil to the correct level See Engine Lubrication OIL Standard Procedure 25 Fill the cooling system Refer to Cooling Stan...

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