Page 1 2010 Jeep Wrangler Sport 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 2010 ENGINE 3.8L - Service Information - Wrangler 2010 ENGINE 3.8L - Service Information - Wrangler DESCRIPTION DESCRIPTION Fig. 1: ENGINE IDENTIFICATION Courtesy of CHRYSLER LLC The 3.8 Liter (231 cu.
Page 2 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections of malfunctions. See PERFORMANCE. See MECHANICAL. For fuel system diagnosis, refer to Non-DTC Diagnostics/Driveability - Gas - Diagnosis and Testing .
Page 3 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3. Intake manifold leakage. 3. Inspect intake manifold, manifold gasket, and vacuum hoses. 4. Faulty ignition coil(s).
Page 4 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Contamination in fuel system. 4. Clean system and replace fuel filter. MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase.
Page 5: Oil Leaks
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler (b) Run engine to operating temperature. (c) Change engine oil and filter again. 5. Excessive bearing clearance. 5. Measure bearings for correct clearance. Repair as necessary. 6. Excessive end play.
Page 6: Engine Oil Leak Inspection
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler assembly. 6. Valve stem seal(s) worn or 6. Replace seal(s). damaged. ENGINE OIL LEAK INSPECTION Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed: 1.
Page 7: Leak Inspection
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler CAUTION: Do not exceed 20.6 kPa (3 psi). CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
Page 8: Cylinder Combustion Pressure Leakage Test
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
Page 9: Standard Procedure
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.
Page 10 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Abrasive pad or paper to clean cylinder block and head. High speed power tool with an abrasive pad or a wire brush (2,3). Fig. 3: PROPER TOOL USAGE FOR SURFACE PREPARATION...
Page 11 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 4: Plastigage Placed in Lower Shell-Typical Courtesy of CHRYSLER LLC 1 - PLASTIGAGE Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1.
Page 12 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
Page 13 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. CAUTION: DO NOT use starter motor to rotate the engine, severe damage may occur.
Page 14 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 5: Core Hole Plug Removal Courtesy of CHRYSLER LLC 1 - CYLINDER BLOCK 2 - REMOVE PLUG WITH PLIERS 3 - STRIKE HERE WITH HAMMER 4 - DRIFT PUNCH 5 - CUP PLUG Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug.
Page 15 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 6: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Perform fuel pressure release procedure. Refer to Fuel System - Standard Procedure . 2. Disconnect negative battery cable.
Page 16 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Evacuate and recover the air conditioning. 5. Disconnect the throttle control connectors (3) from the throttle body. Fig. 8: PCV VALVE LOCATION 3.8L Courtesy of CHRYSLER LLC 6.
Page 17 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 7. Remove the front splash shield (1). 8. Drain the cooling system. 9. Disconnect the upper radiator hose from the thermostat housing and the lower radiator hose from the radiator.
Page 18 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 11: MAP SENSOR 3.8L Courtesy of CHRYSLER LLC 12. Disconnect the throttle position (TP), idle air control (IAC) motor, oxygen (HO2), cam position (CMP), manifold absolute pressure (MAP) (2) and the two engine wiring harness connectors. Free the harness from the cover studs and set harness aside.
Page 19 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 14. Disconnect the EVAP hose from the throttle body. 15. Remove the EGR tube (1). Refer to Emissions Control/Exhaust Gas Recirculation/VALVE, Exhaust Gas Recirculation (EGR) - Removal .
Page 20 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 14: FUEL RAIL 3.8L Courtesy of CHRYSLER LLC 18. Disconnect the fuel line from fuel rail (4). 19. Remove engine wiring harness retainer from left cylinder head cover and oil level indicator tube.
Page 21 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 16: Remove/Install Discharge Line Courtesy of CHRYSLER LLC 22. Disconnect the A/C electrical connector. 23. Disconnect the A/C discharge line (2) from the compressor. Cover and seal all openings of hoses and compressor.
Page 22 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 18: Locating CKP Sensor Courtesy of CHRYSLER LLC 25. Disconnect the oil pressure sending unit (OPS). 26. Disconnect the coolant hose at the engine oil cooler. 27. Remove the crankshaft sensor (2), (CKP).
Page 23 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 28. Disconnect the in block heater (if equipped). 29. Disconnect the starter wiring (1) and remove starter. Fig. 20: STARTER MOUNTING 3.8L Courtesy of CHRYSLER LLC 30. Remove the starter (1).
Page 24 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 21: O2 SENSORS LEFT SIDE Courtesy of CHRYSLER LLC 33. Disconnect the left side oxygen sensors (1,2). Fig. 22: O2 SENSORS RIGHT SIDE Courtesy of CHRYSLER LLC 34.
Page 25: Installation
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 23: MOUNTING BOLTS Courtesy of CHRYSLER LLC 37. Remove the power steering pump mounting bolts (2) and pump, with hoses attached. 38. Remove the engine mount thru bolts.
Page 26 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 25: 3.8L STRUCTURAL COVER Courtesy of CHRYSLER LLC 1. Position the engine in the vehicle. 2. Install the transmission bellhousing to engine mounting bolts. Refer to Transmission and Transfer Case/Manual - Installation .
Page 27 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 26: Locating CKP Sensor Courtesy of CHRYSLER LLC 6. Install the crank position sensor (2) (CKP). Fig. 27: STARTER MOUNTING 3.8L Courtesy of CHRYSLER LLC 7. Install the starter (1). Refer to Electrical/Starting/STARTER - Installation .
Page 28 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC 8. Install the flex plate inspection cover. (If equipped). 9. Connect the starter wiring (1). Refer to Electrical/Starting/STARTER - Installation . Fig. 29: O2 SENSORS RIGHT SIDE Courtesy of CHRYSLER LLC 10.
Page 29 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 30: O2 SENSORS LEFT SIDE Courtesy of CHRYSLER LLC 13. Connect the left side O2 sensors (1, 2). 14. Connect the in block heater (if equipped). 15. Connect the coolant hose at the engine oil cooler.
Page 30 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 16. Connect the oil pressure sending unit (OPS) wiring harness connector. 17. Install the upper intake manifold (3). See Engine/Manifolds/MANIFOLD, Intake - Installation. Fig. 32: EGR TUBE FLANGE Courtesy of CHRYSLER LLC 18.
Page 31 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 33: MAP SENSOR 3.8L Courtesy of CHRYSLER LLC 20. Route the engine harness to the left cylinder head and attach the purge solenoid. 21. Connect the throttle position (TP), idle air control (IAC) motor, oxygen (H02), cam position (CMP), manifold absolute pressure (MAP) (2), and the engine wiring harness connectors.
Page 32 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC 23. Connect the A/C suction line (2) at the compressor and compressor electrical connector. Refer to Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Installation .
Page 33 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 25. Connect the fuel line (4) to the fuel rail. Fig. 38: GENERATOR MOUNTING 3.8L Courtesy of CHRYSLER LLC 26. Install the generator (3). Refer to Electrical/Charging/GENERATOR - Installation .
Page 34 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 28. Install the drive belt. Fig. 40: THROTTLE BODY 3.8L Courtesy of CHRYSLER LLC 29. Connect the radiator, coolant reservoir and heater hoses. 30. Connect the throttle wiring harness (ETC) (3).
Page 35 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 31. Install the PCV hose (1). 32. Fill the cooling system. Refer to Cooling - Standard Procedure . Fig. 42: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 33.
Page 36: Specification
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 43: FRONT SPLASH SHIELD Courtesy of CHRYSLER LLC 36. Install the front splash shield (1). 37. Connect negative cable to battery. 38. Start engine and run until operating temperature is reached.
Page 37 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Compression Pressure-Minimum 689.5 kPa 100 psi. Cylinder Compression (Max. Difference Between Cylinders CYLINDER BLOCK DESCRIPTION SPECIFICATION Metric Standard Cylinder Bore Diameter 95.993-96.007 mm 3.7792-3.780 in. (Standard) 3.8L Out of Round (Service Limits) 0.076 mm...
Page 38 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Clearance in Bore @ Size -0.005-0.039 mm -0.0002-0.0015 in. Location (New) Weight 3.8L 426 ± 5 grams 15.03 ± 0.1764 oz. PISTON PINS DESCRIPTION SPECIFICATION Metric Standard Type Press Fit in Rod (Serviced as a Assembly) Clearance in Piston @ 21C (70°F)
Page 39 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Journal Diameter 50.724-50.775 mm 1.997-1.999 in. 50.317-50.368 mm 1.9809-1.9829 in. 49.936-49.987 mm 1.9659-1.9679 in. 49.530-49.581 mm 1.9499-1.9520 in. Bearing Clearance-Diametrical 0.025-0.101 mm 0.001-0.004 in. Bearing Clearance 0.127 mm 0.005 in.
Page 40 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Face Angle-Exhaust 45-45.5° Head Diameter-Intake 47.87-48.13 mm 1.88-1.89 in. Head Diameter-Exhaust 35.37-35.63 mm 1.39-1.40 in. Valve Lift (Zero Lash)-Intake and 11.0 mm 0.433 in. Exhaust-3.8L Valve Length-Intake 125.84-126.6 mm 4.95-4.98 in.
Page 41 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Method) Max Allowable-Exhaust (Rocking 0.414 mm 0.016 in. Method) PUSH RODS DESCRIPTION SPECIFICATION Metric Standard Length 135.438 mm 5.33 in. VALVE SPRING DESCRIPTION SPECIFICATION Metric Standard Free Length-Type A 51.1 mm...
Page 42 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Outer Rotor Clearance (Max) 0.039 mm 0.015 in. Outer Rotor Diameter (Min) 79.95 mm 3.148 in. Tip Clearance Between Rotors 0.20 mm 0.008 in. (Max) TORQUE TORQUE SPECIFICATIONS DESCRIPTION Ft.
Page 43: Special Tools
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler - M8 Bolt - M10 Bolt Water Pump - Bolts Water Pump Pulley - Bolts SPECIAL TOOLS SPECIAL TOOLS Fig. 44: PULLER - 1023 Courtesy of CHRYSLER LLC Fig.
Page 44 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC Fig. 47: REMOVER, SPROCKET - 8539 Courtesy of CHRYSLER LLC Fig. 48: CYLINDER INDICATOR - C-119 Courtesy of CHRYSLER LLC Fig. 49: COMPRESSOR, VALVE SPRING - 8453 Courtesy of CHRYSLER LLC viernes, 1 de octubre de 2021 05:18:30 p.
Page 45 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 50: COMPRESSOR, VALVE SPRING - C-3422-D Courtesy of CHRYSLER LLC Fig. 51: ADAPTER, VALVE SPRING - 8464 Courtesy of CHRYSLER LLC Fig. 52: REMOVER & INSTALLER - C-4129-A Courtesy of CHRYSLER LLC Fig.
Page 46 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 54: INSTALLER/PROTECTOR - C-4992 Courtesy of CHRYSLER LLC Fig. 55: INSTALLER, SEAL - 6926 Courtesy of CHRYSLER LLC Fig. 56: REMOVER/INSTALLER - C-3059A Courtesy of CHRYSLER LLC Fig.
Page 47 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 59: TESTER, COOLING SYSTEM - 7700-A Courtesy of CHRYSLER LLC Fig. 60: BLOC-CHEK-KIT - C-3685-A Courtesy of CHRYSLER LLC Fig. 61: PRESSURE TRANSDUCER, RPL - CH7059 Courtesy of CHRYSLER LLC viernes, 1 de octubre de 2021 05:18:30 p.
Page 48: Air Intake System
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 62: ADAPTER, PRESSURE PEP - 8116 Courtesy of CHRYSLER LLC Fig. 63: GUIDE PINS - 8189 Courtesy of CHRYSLER LLC Fig. 64: DECAY TOOL, FUEL - 8978...
Page 49: Installation
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 65: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Disconnect the IAT sensor (2). 2. Disconnect the CCV hose. 3. Separate the air inlet tube from the throttle body.
Page 50 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 66: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Install the air filter element into air box. 2. Move cover so that the tabs insert into the air cleaner housing.
Page 51 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 67: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Disconnect the negative battery cable. 2. Disconnect the inlet air temperature sensor (2). 3. Disconnect the CCV hose from the air cleaner cover.
Page 52: Cylinder Head
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 68: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Install air cleaner housing into vehicle and onto the locating pin. 2. Install bolt to hold air cleaner housing to the upper radiator cross member.
Page 53 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 69: VALVE COMPONENTS Courtesy of CHRYSLER LLC 1 - VALVE LOCKS 5 - SPRING SEATS 2 - RETAINERS 6 - CYLINDER HEAD 3 - VALVE SPRINGS 7 - VALVE - EXHAUST...
Page 54 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Engine overheating Loss of coolant Excessive steam (white smoke) emitting from exhaust Coolant foaming CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test.
Page 55 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 70: INTAKE TORQUE SEQUENCE 3.8L Courtesy of CHRYSLER LLC 1. Drain the cooling system. Refer to Cooling - Standard Procedure . 2. Disconnect negative cable from battery.
Page 56 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 71: OIL LEVEL INDICATOR AND TUBE Courtesy of CHRYSLER LLC 1 - INDICATOR 2 - BOLT 3 - TUBE 4. Remove the cylinder head covers. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
Page 57 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS 7. Remove exhaust manifold(s). See Engine/Manifolds/MANIFOLD, Exhaust - Removal. 8. Remove rocker arm and shaft assemblies (2). See Engine/Cylinder Head/ROCKER ARM, Valve - Removal.
Page 58 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 74: Checking Cylinder Head Flatness-Typical Courtesy of CHRYSLER LLC 1. Before cleaning, check for leaks, damage and cracks. 2. Clean cylinder head and oil passages. See Engine/Cylinder Head - Cleaning.
Page 59 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 75: CYLINDER HEAD GASKET Courtesy of CHRYSLER LLC 1 - CYLINDER HEAD GASKET 2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT BANK) 1. Clean all sealing surfaces of engine block and cylinder heads. See Engine - Standard Procedure.
Page 60 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 77: CYLINDER HEAD TIGHTENING SEQUENCE Courtesy of CHRYSLER LLC 5. Tighten the cylinder head bolts 1-8 in the sequence shown in illustration . Using the 4 step torque turn...
Page 61 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 79: INTAKE TORQUE SEQUENCE 3.8L Courtesy of CHRYSLER LLC 10. Install the exhaust manifolds. See Engine/Manifolds/MANIFOLD, Exhaust - Installation. 11. Install new O-ring on oil level indicator tube. Install oil level indicator tube assembly .
Page 62 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1 - CYLINDER HEAD COVER 2 - BOLT 3 - SEAL (SERVICED WITH BOLT) 4 - GASKET The cylinder head covers (1) are made of composite material. The covers are sealed with steel reinforced silicon rubber gaskets.
Page 63 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 82: PCV VALVE LOCATION 3.8L Courtesy of CHRYSLER LLC 3. Disconnect PCV hose (1) from cylinder head cover. Fig. 83: GENERATOR MOUNTING 3.8L Courtesy of CHRYSLER LLC 4.
Page 64 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 6. Remove cylinder head cover and gasket. Installation INSTALLATION Fig. 84: PCV VALVE LOCATION 3.8L Courtesy of CHRYSLER LLC 1. Clean cylinder head and cylinder head cover mating surfaces. Inspect cylinder head cover surface for flatness.
Page 65 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 85: IGNITION COIL PACK 3.8L Courtesy of CHRYSLER LLC 6. Install the ignition coil pack (1) and plug wires. Fig. 86: GENERATOR MOUNTING 3.8L Courtesy of CHRYSLER LLC 7.
Page 66 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler COVER(S), CYLINDER HEAD, RIGHT Removal REMOVAL Fig. 87: CYLINDER HEAD COVER GASKET Courtesy of CHRYSLER LLC 1 - CYLINDER HEAD COVER 2 - BOLT 3 - SEAL (SERVICED WITH BOLT) 4 - GASKET 1.
Page 67: Cylinder Head Cover
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 88: CYLINDER HEAD COVER GASKET Courtesy of CHRYSLER LLC 1 - CYLINDER HEAD COVER 2 - BOLT 3 - SEAL (SERVICED WITH BOLT) 4 - GASKET 1. Clean cylinder head and cylinder head cover mating surfaces. Inspect cylinder head cover surface for flatness.
Page 68 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 2 - BOLT 3 - SEAL (SERVICED WITH BOLT) 4 - GASKET 5. Install cylinder head cover and bolts (2). 6. Tighten cylinder head cover bolts to 12 N.m (105 in. lbs.).
Page 69 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 90: ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS 1. Remove the cylinder head cover(s). See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
Page 70 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 91: ROCKER ARM RETAINER - REMOVAL Courtesy of CHRYSLER LLC 1 - ADJUSTABLE PLIERS 3 - ROCKER ARM RETAINER 2 - BILLETED ROCKER SHAFT BOLT CAUTION: Do not attempt to drive the billeted bolt from the rocker shaft. This can damage the rocker arm retainer and bolt assembly.
Page 71 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 92: ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1 - BOLT (ROCKER SHAFT 5 - ROCKER ARM - OIL FEED - LONGER EXHAUST LENGTH) 2 - SHAFT 6 - WASHER RETAINER/SPACER - 21.5...
Page 72 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler INSTALLATION Fig. 93: ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS CAUTION: Ensure the longer shaft retaining bolt is installed in the proper location on the rocker shaft.
Page 73 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 94: VALVE STEM SEAL Courtesy of CHRYSLER LLC The valve stem seals are made of Viton rubber. The seals are positioned over the valve stem and seated on the valve guide .
Page 74 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 95: VALVE SPRING Courtesy of CHRYSLER LLC 1 - VALVE SPRING (TOP - SMALLER DIAMETER) There are two interchangeable, floating (spring rotates during operation), valve spring designs. Type A may be identified by the counterclockwise (spring spirals down and to the left) appearance, And Type B may be identified by the clockwise (spring spirals down and to the right) appearance.
Page 75 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 96: VALVE COMPONENTS Courtesy of CHRYSLER LLC 1 - VALVE LOCKS 5 - SPRING SEATS 2 - RETAINERS 6 - CYLINDER HEAD 3 - VALVE SPRINGS 7 - VALVE - EXHAUST...
Page 76 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 3. Slowly release the spring tension and remove the valve spring and retainer. 4. For removal of the valve stem seal, see Engine/Cylinder Head/SEAL(S), Valve Guide - Removal.
Page 77 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 2 - ROCKER SHAFT BOLTS 4. Remove rocker arms and shaft (1). See Engine/Cylinder Head/ROCKER ARM, Valve - Removal. 5. Rotate engine until the piston in the cylinder bore requiring spring removal is at TDC.
Page 78 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 101: Testing Valve Spring Courtesy of CHRYSLER LLC 1 - SPECIAL TOOL C-647 NOTE: The are two different types of valve springs used that are interchangeable, but have different specifications.
Page 79 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 102: VALVE SPRING COMPRESSOR Courtesy of CHRYSLER LLC 1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR 2 - SPECIAL TOOL 8464 ADAPTER 1. If removed, install a new valve stem seal. See Engine/Cylinder Head/SEAL(S), Valve Guide - Installation.
Page 80 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1 - VALVE SPRING RETAINER 2 - VALVE INSTALLED HEIGHT 3 - CYLINDER HEAD SURFACE 4 - VALVE SPRING SEAT SURFACE 5 - VALVE SPRING INSTALLED HEIGHT 4. Slowly release the spring tension. Ensure the retainer locks are seated properly .
Page 81 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 105: ROCKER ARMS AND SHAFT Courtesy of CHRYSLER LLC 1 - ROCKER ARMS AND SHAFT ASSEMBLY 2 - ROCKER SHAFT BOLTS 4. Install rocker arms and shaft assembly (1).
Page 82 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 106: VALVE FACE AND SEAT Courtesy of CHRYSLER LLC 1 - VALVE FACE WIDTH 2 - VALVE FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA The intake and exhaust valves and seats are machined to specific angles .
Page 83: Valve Seats
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. Inspect the remaining margin after the valves are refaced . See Engine - Specifications. VALVE SEATS Fig. 108: Refacing Valve Seats Courtesy of CHRYSLER LLC 1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD...
Page 84: Dial Indicator
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 109: Measurement of Valve Seat Runout Courtesy of CHRYSLER LLC 1 - DIAL INDICATOR 2. Measure the concentricity of valve seat using dial indicator . Total runout should not exceed 0.051 mm (0.002 in.) total indicator reading.
Page 85 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler by measuring from valve tip to spring seat . Remove valve from cylinder head and grind valve tip until within specifications. Check valve tip for scoring. The tip chamfer should be reground (if necessary) to prevent seal damage when the valve is installed.
Page 86 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 112: VALVE COMPONENTS Courtesy of CHRYSLER LLC 1 - VALVE LOCKS 5 - SPRING SEATS 2 - RETAINERS 6 - CYLINDER HEAD 3 - VALVE SPRINGS 7 - VALVE - EXHAUST...
Page 87 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 113: Intake and Exhaust Valves Courtesy of CHRYSLER LLC 1 - MARGIN 2 - FACE 3 - STEM 4 - VALVE SPRING RETAINER LOCK GROOVES 1. Clean and inspect valves thoroughly. Replace burned, warped and cracked valves.
Page 88: Installation
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Measure valve stem-to-guide clearance as follows: 3. Install valve into cylinder head so it is 15 mm (0.590 inch.) off the valve seat. A small piece of hose may be used to hold valve in place.
Page 89: Engine Block
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 116: VALVE STEM SEAL Courtesy of CHRYSLER LLC 3. Install new seals on all valve stems and over valve guides Install valve springs and valve retainers 4. Install the valve springs. See Engine/Cylinder Head/SPRING(S), Valve - Installation.
Page 90 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 117: CYLINDER BORE CROSS-HATCH PATTER Courtesy of CHRYSLER LLC 1 - CROSS-HATCH PATTERN 2 - 40°-60° 1. Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure.
Page 91 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler CLEANING CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent. INSPECTION INSPECTION ENGINE BLOCK 1. Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
Page 92 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 118: CONNECTING ROD TO CYLINDER IDENTIFICATION Courtesy of CHRYSLER LLC 1 - PAINT MARK OR SCRIBE The bearing caps are not interchangeable and should be marked (1) at removal to ensure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps.
Page 93 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 119: CONNECTING ROD BEARING CLEARANCE Courtesy of CHRYSLER LLC The connecting rod bearing clearances can be determined by use of Plastigage or the equivalent. The following is the recommended procedure for the use of Plastigage: 1.
Page 94: Crankshaft Bearing Oil Clearance
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 120: Main Bearing Cap Identification Courtesy of CHRYSLER LLC Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable.
Page 95 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 122: Plastigage Placed in Lower Shell Courtesy of CHRYSLER LLC Inspect the crankshaft bearing journals. Engine crankshaft bearing clearances can be determined by use of Plastigage (1) or the equivalent. The following is the recommended procedures for the use of Plastigage with the engine in the vehicle or engine on a repair stand.
Page 96 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 123: Plastigage Placed in Lower Shell Courtesy of CHRYSLER LLC 2. Alternative Method: a. Support the weight of the crankshaft with a jack under the counterweight adjacent to the bearing being checked.
Page 97 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler cap. 2. Remove oil from journal and bearing shell. 3. Cut Plastigage (1) to same length as width of the bearing and place it in parallel with the journal axis (1).
Page 98 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 126: Check for Stretched Bolts Courtesy of CHRYSLER LLC 1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE...
Page 99 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC 5. Install each main cap and tighten bolts finger tight. 6. Tighten number 1, 3 and 4 main cap bolts to 41 N.m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
Page 100 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Operation OPERATION The camshaft is driven by the crankshaft through a timing chain and sprockets. The camshaft has precisely machined (egg-shaped) lobes to provide accurate valve timing and duration.
Page 101 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. Remove the radiator and cooling fans from the vehicle. 2. Remove the cylinder heads. See Engine/Cylinder Head - Removal. 3. Remove the timing chain and camshaft sprocket. Refer to CHAIN and SPROCKETS, Timing.
Page 102 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 131: CAMSHAFT - INSPECTION Courtesy of CHRYSLER LLC 1 - UNWORN AREA 2 - ACTUAL WEAR 3 - BEARING JOURNAL 4 - LOBE 5 - WEAR ZONE 1.
Page 103 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 132: CAMSHAFT AND BEARINGS Courtesy of CHRYSLER LLC 1 - CAMSHAFT 2 - THRUST PLATE 3 - BOLT 4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK) 1. Lubricate camshaft lobes (1) and camshaft bearing journals (4) with engine oil.
Page 104 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 12. Install the radiator and cooling fan. COVER, STRUCTURAL DUST Removal REMOVAL Fig. 134: 3.8L STRUCTURAL COVER Courtesy of CHRYSLER LLC 1. Raise vehicle on hoist. 2. Remove the bolts retaining structural cover to transmission (1, 2).
Page 105 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 135: 3.8L STRUCTURAL COVER Courtesy of CHRYSLER LLC CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover or the oil pan.
Page 106 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 136: CRANKSHAFT AND BLOCK - 3.8L Courtesy of CHRYSLER 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.
Page 107: Measuring Crankshaft End Play
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Standard Procedure MEASURING CRANKSHAFT END PLAY Fig. 137: CRANKSHAFT END PLAY TYPICAL Courtesy of CHRYSLER LLC 1. Mount a dial indicator to front of engine with the locating probe on nose of crankshaft.
Page 108 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 138: CONNECTING ROD TO CYLINDER IDENTIFICATION Courtesy of CHRYSLER LLC 1 - PAINT MARK OR SCRIBE 1. Remove the engine assembly. See Engine - Removal. 2. Mount engine on an engine stand.
Page 109 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 139: CRANKSHAFT AND BLOCK - 3.8L Courtesy of CHRYSLER 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.
Page 110 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 13. Remove the main bearing cap bolts (4). 14. Remove the main bearing caps (1, 2, 3, 5). 15. Remove the crankshaft (11) from engine block. Installation INSTALLATION Fig.
Page 111 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 10 - MAIN BEARING - UPPER 11 - CRANKSHAFT 12 - MAIN BEARING - LOWER 1. Lubricate with engine oil and install the crankshaft main bearing halves in the engine block.
Page 112 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 142: CRANKSHAFT AND BLOCK - 3.8L Courtesy of CHRYSLER 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.
Page 113 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 6. Install and tighten the NEW cross bolts and washer assemblies (8) to 61 N.m (45 ft. lbs.). 7. Position and install the connecting rod and bearing caps on the crankshaft. See Engine/Engine Block/BEARING(S), Connecting Rod - Standard Procedure.
Page 114 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler INSTALLATION Fig. 144: CRANKSHAFT DAMPER Courtesy of CHRYSLER LLC 1 - FORCING SCREW/NUT FROM SPECIAL TOOL 8452 2 - VIBRATION DAMPER 3 - THRUST BEARING/WASHER 1. Install crankshaft vibration damper using the forcing screw, nut, and thrust bearing/washer (3) from Special Tool 8452 (1).
Page 115 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 145: FLEX PLATE Courtesy of CHRYSLER LLC 1 - FLEX PLATE 2 - BOLT (QTY. 8) 3 - BACKING PLATE 1. Remove the transmission. 2. Remove flex plate attaching bolts.
Page 116 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1 - FLEX PLATE 2 - BOLT (QTY. 8) 3 - BACKING PLATE 1. Position the flex plate (1) with backing plate (3) on the crankshaft. 2. Apply Mopar® Lock AND Seal Adhesive to the eight flex plate bolts (2).
Page 117 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 147: HYDRAULIC LIFTERS Courtesy of CHRYSLER LLC 1 - YOKE RETAINER 2 - BOLT - YOKE RETAINER 3 - ALIGNING YOKE 4 - HYDRAULIC LIFTER The hydraulic lifters are a roller type design and are positioned in the cylinder block with the lubrication whole facing upward.
Page 118 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Before disassembling any part of the engine to correct lifter noise, check the engine oil pressure. See Engine/Lubrication - Diagnosis and Testing. Check engine oil level. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark.
Page 119 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 148: HYDRAULIC LIFTERS Courtesy of CHRYSLER LLC 1 - YOKE RETAINER 2 - BOLT - YOKE RETAINER 3 - ALIGNING YOKE 4 - HYDRAULIC LIFTER 1. Remove the cylinder head(s). See Engine/Cylinder Head - Removal.
Page 120 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 149: LIFTER LUBRICATION HOLE Courtesy of CHRYSLER LLC 1. Lubricate the lifters with engine oil. NOTE: Position the lifter in bore with the lubrication hole facing upward.
Page 121 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 150: HYDRAULIC LIFTERS Courtesy of CHRYSLER LLC 1 - YOKE RETAINER 2 - BOLT - YOKE RETAINER 3 - ALIGNING YOKE 4 - HYDRAULIC LIFTER 3. Install lifter aligning yokes (3).
Page 122 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Removal REMOVAL NOTE: Any time the rear crank oil seal has been removed from the engine block, a new seal assembly must be installed. Do not reuse a real crank oil seal assembly once it has been removed.
Page 123 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 152: CRANKSHAFT REAR OIL SEAL Courtesy of CHRYSLER LLC CAUTION: Before installing a new rear oil seal assembly, ensure that the plastic installation sleeve (1) is present in the seal assembly. The new seal cannot be properly installed without the plastic installation sleeve, and if the seal assembly is installed without it, oil leakage will result.
Page 124: Piston Ring Fitting
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler PISTON RING FITTING Fig. 153: Check Gap on Piston Rings Courtesy of CHRYSLER LLC 1 - FEELER GAUGE 1. Wipe cylinder bore clean. Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm (0.50 in.) from top of cylinder bore.
Page 125 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Removal REMOVAL 1. Remove piston and connecting rod. See Engine/Engine Block/ROD, Piston and Connecting - Removal. 2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool.
Page 126 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 156: Installing Side Rail Courtesy of CHRYSLER LLC 1 - SIDE RAIL END 1. Oil ring expander (5). 2. Lower oil ring side rail (4). 3. Upper oil ring side rail.
Page 127 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 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 5.
Page 128 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1 - STRETCHED BOLT 2 - THREADS ARE NOT STRAIGHT ON LINE 3 - THREADS ARE STRAIGHT ON LINE 4 - UNSTRETCHED BOLT NOTE: The connecting rod cap bolts (4) should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads.
Page 129: Fitting Pistons
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 160: Checking Connecting Rod To Crankshaft Journal Flange Clearance Courtesy of CHRYSLER LLC 1. Before installing the bolts, the threads should be lubricated with engine oil. 2. Install bolts finger tight then alternately torque each bolt to assemble the cap properly.
Page 130 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 161: CONNECTING ROD TO CYLINDER IDENTIFICATION Courtesy of CHRYSLER LLC 1 - PAINT MARK OR SCRIBE NOTE: Refer to the connecting rod Description before beginning repair. See Engine/Engine Block/ROD, Piston and Connecting - Description.
Page 131 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 162: PISTON AND CONNECTING ROD Courtesy of CHRYSLER LLC 1 - "F" TOWARD FRONT OF ENGINE 2 - RING COMPRESSOR 3 - SPECIAL TOOL 8189 4 - OIL SQUIRT HOLE 6.
Page 132 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 163: PISTON RING END GAP POSITION Courtesy of CHRYSLER LLC 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO.
Page 133 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 164: PISTON AND CONNECTING ROD Courtesy of CHRYSLER LLC 1 - "F" TOWARD FRONT OF ENGINE 2 - RING COMPRESSOR 3 - SPECIAL TOOL 8189 4 - OIL SQUIRT HOLE 2.
Page 134 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 165: Identifying Proper Piston Orientation Courtesy of CHRYSLER LLC 1 - ARROW FACES FRONT OF ENGINE 5. The pistons are marked with an arrow (1) on top of the piston. Install piston with this mark positioned to front of engine on both cylinder banks.
Page 135 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 166: Piston and Connecting Rod Positioning Courtesy of CHRYSLER LLC 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE 6. The connecting rod oil squirt hole (2) faces the major thrust (right) side of the engine block (1).
Page 136 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 167: PISTON AND CONNECTING ROD Courtesy of CHRYSLER LLC 1 - "F" TOWARD FRONT OF ENGINE 2 - RING COMPRESSOR 3 - SPECIAL TOOL 8189 4 - OIL SQUIRT HOLE 7.
Page 137 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 11. Install the cylinder heads. See Engine/Cylinder Head - Installation. 12. Install the oil pan. See Engine/Lubrication/PAN, Oil - Installation. 13. Fill engine crankcase with proper oil to correct level. See Engine/Lubrication/OIL - Standard Procedure.
Page 138 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 169: CRANKSHAFT FRONT SEAL REMOVAL Courtesy of CHRYSLER LLC 1 - SEAL 2 - SPECIAL TOOL 6341A 5. Remove oil seal (1) by turning the forcing screw until the seal disengages from the cover.
Page 139: Engine Mounting
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 2. Position new seal (2) over the guide with the seal spring in the direction of the engine front cover. 3. Install seal using Special Tool C-4992-1 (1) until seal is flush with cover.
Page 140: Automatic Transmissions
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 171: Rear Mount (Manual Transmission) Courtesy of CHRYSLER LLC 1 - CUSHION 2 - BRACKET 3 - SKID PLATE 1. Disconnect negative cable from battery. 2. Raise the vehicle and support the transmission.
Page 141: Manual Transmission
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 172: Rear Mount (AutomaticTransmission) Courtesy of CHRYSLER LLC 1 - BRACKET 2 - CUSHION 3 - BRACKET 1. Disconnect negative cable from battery. 2. Raise the vehicle and support the transmission.
Page 142: Automatic Transmission
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 173: Rear Mount (Manual Transmission) Courtesy of CHRYSLER LLC 1 - CUSHION 2 - BRACKET 3 - SKID PLATE 1. Position the skid plate to the studs of the support cushion and install the nuts. Tighten the nuts to 28 N.m (21 ft.
Page 143 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 174: Rear Mount (AutomaticTransmission) Courtesy of CHRYSLER LLC 1 - BRACKET 2 - CUSHION 3 - BRACKET 1. Position the skid plate to the studs of the support cushion and install the nuts. Tighten the nuts to 28 N.m (21 ft.
Page 144: Operation
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler DESCRIPTION The lubrication system is a full flow filtration pressure feed type. The oil pump is mounted in the timing chain cover and is driven by the crankshaft...
Page 145 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. Disconnect and remove oil pressure switch. See Engine/Lubrication/SWITCH, Oil Pressure - Removal. 2. Install Special Tools C-3292A Gauge with 8406 Adaptor. For Special Tool identification, see Engine - Special Tools.
Page 146: Engine Oil And Filter Change
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 177: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 1. Wipe oil filter adapter base clean and inspect gasket contact surface. 2. Lubricate gasket of new filter with clean engine oil.
Page 147 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 178: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC Change engine oil at mileage and time intervals described in the Maintenance Schedule. Refer to Vehicle Quick Reference/Maintenance Schedules - Description .
Page 148: Engine Oil Level Check
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine.
Page 149 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 180: 3.8L STRUCTURAL COVER Courtesy of CHRYSLER LLC 4. Remove the structural cover fasteners (1, 2) and structural cover. See Engine/Engine Block/COVER, Structural Dust - Removal. Fig. 181: Upper Oil Pan-To-Engine Block Bolts...
Page 150 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Cleaning CLEANING 1. Clean oil pan with solvent and wipe dry with a clean cloth. 2. Clean all gasket material from mounting surfaces of pan and block. 3. Clean oil screen and pick-up tube in clean solvent.
Page 151 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 183: Upper Oil Pan-To-Engine Block Bolts Courtesy of CHRYSLER LLC 3. Install oil pan and tighten fasteners (1) to 12 N.m (105 in. lbs.). Fig. 184: 3.8L STRUCTURAL COVER Courtesy of CHRYSLER LLC 4.
Page 152 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 185: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 6. Install new oil filter (2). 7. Fill crankcase with oil to proper level. 8. Connect negative cable to battery.
Page 153 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 186: Oil Pump Courtesy of CHRYSLER LLC 1 - CHAIN CASE COVER 2 - OIL PUMP INNER ROTOR 3 - SCREW 4 - OIL PUMP COVER 5 - OIL PUMP OUTER ROTOR The oil pump (1) is contained within the timing chain cover housing.
Page 154 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 187: Disassembling/Assembling Oil Pump Courtesy of CHRYSLER LLC 1 - TIMING CHAIN COVER 2 - SCREWS 3 - INNER ROTOR 4 - OUTER ROTOR 5 - COVER 1.
Page 155 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 188: Checking Oil Pump Cover Flatness Courtesy of CHRYSLER LLC 1 - FEELER GAUGE 2 - OIL PUMP COVER 3 - STRAIGHT EDGE 1. Inspect mating surface of the chain case cover. Surface should be smooth. Replace cover if scratched or grooved.
Page 156 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 190: Measuring Inner Rotor Thickness Courtesy of CHRYSLER LLC 4. If inner rotor thickness measures 7.64 mm (0.301 in.) or less, replace inner rotor . Fig. 191: Measuring Outer Rotor Clearance in Housing...
Page 157 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 192: Measuring Clearance Between Rotors Courtesy of CHRYSLER LLC 1 - FEELER GAUGE 2 - INNER ROTOR 3 - OUTER ROTOR 6. Install inner rotor into chain case cover. If clearance between inner and outer rotors is 0.203 mm (0.008 in.) or more, replace both rotors.
Page 158 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler ONLY if rotors are in specs. Fig. 194: Oil Pressure Relief Valve Courtesy of CHRYSLER LLC 1 - SPRING 2 - RELIEF VALVE 3 - RETAINER CAP 8. Remove oil pressure relief valve. See Engine/Lubrication/VALVE, Oil Pressure Relief - Removal.
Page 159: Switch, Oil Pressure
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler INSTALLATION Fig. 195: Oil Pump Courtesy of CHRYSLER LLC 1 - CHAIN CASE COVER 2 - OIL PUMP INNER ROTOR 3 - SCREW 4 - OIL PUMP COVER 5 - OIL PUMP OUTER ROTOR 1.
Page 160 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler REMOVAL Fig. 196: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 1. Raise vehicle on hoist. 2. Disconnect electrical connector from switch. 3. Remove oil pressure switch (1).
Page 161 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 197: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 1. Install oil pressure switch (1). Torque oil pressure switch to 23 N.m (200 in. lbs.). 2. Connect electrical connector to switch.
Page 162 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 198: Oil Pressure Relief Valve Courtesy of CHRYSLER LLC 1 - SPRING 2 - RELIEF VALVE 3 - RETAINER CAP 1. Remove oil pan. See Engine/Lubrication/PAN, Oil - Removal.
Page 163 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 199: Oil Pressure Relief Valve Courtesy of CHRYSLER LLC 1 - SPRING 2 - RELIEF VALVE 3 - RETAINER CAP NOTE: Always use a new relief valve. Do not reuse the old relief valve, it could have been damaged during removal.
Page 164 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 200: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Disconnect battery negative cable. 2. Remove the fresh air hose (1). 3. Disconnect left cylinder bank spark plug wires.
Page 165 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Remove heat shield attaching bolts. 5. Remove bolts attaching exhaust to manifold. 6. Disconnect the left side oxygen sensors (1,2). 7. Remove bolts attaching exhaust manifold to cylinder head.
Page 166 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. Position exhaust manifold (1) on cylinder head. Install bolts to center runner (cylinder #4) and initial tighten to 2.8 N.m (25 in. lbs.). 2. Position heat shield (2) on manifold.
Page 167 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 204: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Disconnect battery negative cable. 2. Separate the exhaust pipe at the exhaust manifold. 3. Remove the air cleaner hose (1) and housing.
Page 168 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Disconnect the TPS, IAC and purge vacuum hose from the throttle body. 5. Disconnect the spark plug wires at the spark plugs. 6. Disconnect the oxygen sensors (1, 2).
Page 169: Manifold, Intake
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler tighten to 2.8 N.m (25 in. lbs.). 2. Install the remaining manifold attaching bolts. Tighten all bolts to 23 N.m (200 in. lbs.). 3. Connect the oxygen sensors (1,2).
Page 170 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 208: INTAKE TORQUE SEQUENCE 3.8L Courtesy of CHRYSLER LLC The intake system is made up of an upper and lower intake manifold. The upper intake manifold is made of a composite material for the 3.8L engine.
Page 171 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Repair as required. Standard Procedure MANIFOLD STRIPPED THREAD REPAIR The composite upper intake manifold thread bosses, if stripped out, can be repaired by utilizing a repair screw available through Mopar®...
Page 172: Parts Required
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 209: Manifold Port (Nipple) Repair Courtesy of CHRYSLER LLC 1 - BRAKE BOOSTER PORT = 1/4"-18 NPT PIPE TAP 1 - LDP/SPEED CONTROL PORT = 1/8"-18 NPT PIPE TAP 2 - DRILL BIT = 7/16"...
Page 173 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 1. File or sand the remaining port back until a flat surface is obtained (plane normal to port axis). 2. Drill out the port base using a 7/16" (brake booster port) or 11/32" (LDP/speed control port ) drill bit.
Page 174 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 211: THROTTLE BODY 3.8L Courtesy of CHRYSLER LLC 4. Disconnect the throttle body (1) electrical connector (3). 5. Disconnect the EVAP hose at the throttle body. Fig. 212: EGR TUBE FLANGE Courtesy of CHRYSLER LLC 6.
Page 175 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 213: MAP SENSOR 3.8L Courtesy of CHRYSLER LLC 7. Disconnect the Manifold Absolute Pressure (MAP) sensor (1) electrical connector (2) at the rear of the intake manifold (3).
Page 176 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 215: PCV VALVE LOCATION 3.8L Courtesy of CHRYSLER LLC 9. Disconnect the PCV hose (1) from the upper intake manifold. Fig. 216: INTAKE TORQUE SEQUENCE 3.8L Courtesy of CHRYSLER LLC 10.
Page 177 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 12. Clean and inspect the upper intake manifold. Cleaning CLEANING 1. Discard gasket(s). 2. Clean all sealing surfaces. Inspection INSPECTION Check manifold for: Damage and cracks. Mounting surface distortion by using a straightedge and thickness gauge.
Page 178 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Position the upper intake manifold onto the lower intake manifold. 5. Apply Mopar® Lock and Seal Adhesive (Medium Strength Threadlocker) to each upper intake manifold bolt. 6. Install the intake manifold bolts and tighten bolts in the sequence shown in illustration to 12 N.m (105 in.
Page 179 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 8. Connect the power brake booster hose (1) at the rear of the intake manifold (2). Fig. 220: MAP SENSOR 3.8L Courtesy of CHRYSLER LLC 9. If removed, install the MAP sensor (1) at the rear of the intake manifold (3) by pushing down on the MAP sensor while rotating clockwise about 1/4 turn.
Page 180 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC 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 material that causes stripped threads.
Page 181 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 223: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 14. Install the air cleaner and air inlet hose assembly (1). 15. Connect the inlet air temperature (IAT) sensor electrical connector (2).
Page 182 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 224: INTAKE TORQUE SEQUENCE 3.8L Courtesy of CHRYSLER LLC 1. Perform fuel system pressure release procedure. Refer to Fuel System - Standard Procedure . 2. Drain the cooling system.
Page 183 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 4. Remove the fuel line (4). Refer to Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure . 5. Remove ignition coil and bracket. 6. Disconnect heater supply hose and engine coolant temperature sensor.
Page 184 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Courtesy of CHRYSLER LLC 10. Remove the intake manifold bolts. 11. Remove lower intake manifold. WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.
Page 185 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 228: SEALER LOCATIONS Courtesy of CHRYSLER LLC 1 - SEALER LOCATIONS 1. Place a bead (approximately 1/4 in. diameter) of Mopar® Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (1).
Page 186 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 230: FUEL RAIL 3.8L Courtesy of CHRYSLER LLC 4. Install the fuel injectors and rail assembly (3). Refer to Fuel System/Fuel Delivery/RAIL, Fuel - Installation . 5. Connect fuel injector electrical harness.
Page 187: Valve Timing
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 7. Connect the heater supply and radiator upper hoses to manifold. 8. Connect the fuel line (4). Refer to Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure .
Page 188: Torque Wrench
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Allow tappet to bleed down to give a solid tappet effect. 8. Install a dial indicator so plunger contacts the #2 intake valve spring retainer as nearly perpendicular as possible.
Page 189 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 234: Measuring Timing Chain Wear Courtesy of CHRYSLER LLC 1 - TORQUE WRENCH 41 N.m (30 ft. lb.) with cylinder heads installed 20 N.m (15 ft. lb.) with cylinder heads removed 3.
Page 190 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 235: 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...
Page 191: Crankshaft Sprocket
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 236: TIMING MARKS Courtesy of CHRYSLER LLC 1 - CAMSHAFT SPROCKET TIMING MARK (DOT) 2 - PLATED LINK 3 - CRANKSHAFT SPROCKET TIMING MARK (DOT) 4 - ARROWS 3.
Page 192 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 237: CRANKSHAFT SPROCKET - REMOVAL Courtesy of CHRYSLER LLC 1 - SPECIAL TOOL 5048 2 - SPECIAL TOOL 8452 3 - SPECIAL TOOL 8450 4 - CRANKSHAFT SPROCKET 5 - SPECIAL TOOL 8539 1.
Page 193 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 238: CRANKSHAFT SPROCKET - INSTALLATION Courtesy of CHRYSLER LLC 1 - SPECIAL TOOL 8452 2 - SPECIAL TOOL 8452 3 - CRANKSHAFT SPROCKET 4 - THRUST BEARING/WASHER...
Page 194 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 239: TIMING MARKS Courtesy of CHRYSLER LLC 1 - CAMSHAFT SPROCKET TIMING MARK (DOT) 2 - PLATED LINK 3 - CRANKSHAFT SPROCKET TIMING MARK (DOT) 4 - ARROWS 1.
Page 195 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 240: TIMING CHAIN COVER AND GASKET Courtesy of CHRYSLER LLC 1 - GASKET 2 - TIMING CHAIN COVER 7. Install the timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.
Page 196 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 241: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 1. Disconnect and isolate the negative battery cable. 2. Drain the cooling system. Refer to Cooling - Standard Procedure .
Page 197 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 3 - A/C COMPRESSOR 4 - WATER PUMP PULLEY 5 - CRANKSHAFT PULLEY 6 - ACCESSORY DRIVE BELT TENSIONER 7 - P/S PUMP PULLEY 8 - ACCESSORY DRIVE BELT 4.
Page 198 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 244: GENERATOR MOUNTING 3.8L Courtesy of CHRYSLER LLC 7. Remove the generator (3). Refer to Electrical/Charging/GENERATOR - Removal . Fig. 245: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 8.
Page 199 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 246: OIL LEVEL INDICATOR AND TUBE Courtesy of CHRYSLER LLC 10. Remove the oil level indicator (1) and tube (2). Fig. 247: Upper Oil Pan-To-Engine Block Bolts Courtesy of CHRYSLER LLC viernes, 1 de octubre de 2021 05:18:33 p.
Page 200 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 11. Remove the structural cover and oil pan. See Engine/Lubrication/PAN, Oil - Removal. Fig. 248: 3.8L Oil Pressure Switch Courtesy of CHRYSLER LLC 12. Disconnect the lower radiator hose.
Page 201 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 15. Remove the power steering pump fasteners (2) and reposition the power steering pump (1). Fig. 250: A/C COMPRESSOR - MOUNTING BOLTS Courtesy of CHRYSLER LLC 16. Remove the A/C compressor mounting bolts (1, 3 and 4) and reposition the A/C compressor (2).
Page 202 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 252: CAMSHAFT POSITION SENSOR LOCATION Courtesy of CHRYSLER LLC 20. Remove the camshaft position (CMP) sensor from the timing chain cover. Refer to Electrical/Ignition Control/SENSOR, Camshaft Position - Removal .
Page 203 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 21. Remove the timing chain cover fasteners (1-7) and remove the timing chain cover. Installation INSTALLATION Fig. 254: 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...
Page 204 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler severe damage may result. 5. Install the timing cover. NOTE: Tighten the M10 bolts (2, 4, 6,) first, then the M8 (1, 3, 5, 7). 6. Install timing chain cover bolts. Tighten the M10 bolts (2, 4, 6) to 54 N.m (40 ft. lbs.) and the M8 bolts (1, 3, 5, 7) to 28 N.m (21 ft.
Page 205: Vibration Damper
2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 256: CRANKSHAFT FRONT SEAL INSTALLATION Courtesy of CHRYSLER LLC 1 - SPECIAL TOOL C-4992-1 2 - SEAL 3 - SPECIAL TOOL C-4992-2 4 - CRANKSHAFT 9. Install the front crankshaft oil seal (2). See Engine/Engine Block/SEAL, Crankshaft Oil - Installation.
Page 206 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 3 - THRUST BEARING/WASHER 10. Install the crankshaft vibration damper (2). See Engine/Engine Block/DAMPER, Vibration - Installation. 11. Install the vibration damper bolt. Tighten bolt to 54 N.m (40 ft. lbs.).
Page 207 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 259: CAMSHAFT POSITION SENSOR LOCATION Courtesy of CHRYSLER LLC 16. Install the camshaft position (CMP) sensor. Refer to Electrical/Ignition Control/SENSOR, Camshaft Position - Installation . Fig. 260: A/C COMPRESSOR - MOUNTING BOLTS Courtesy of CHRYSLER LLC 17.
Page 208 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 261: OIL LEVEL INDICATOR AND TUBE Courtesy of CHRYSLER LLC The upper bolt (1) at the front of the compressor. The lower bolt (4) at the front of the compressor.
Page 209 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 262: GENERATOR MOUNTING 3.8L Courtesy of CHRYSLER LLC 19. Install the generator (3). Refer to Electrical/Charging/GENERATOR - Installation . Fig. 263: MOUNTING BOLTS Courtesy of CHRYSLER LLC 20.
Page 210 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler Fig. 264: Water Pump Pulley Positioning Courtesy of CHRYSLER LLC 21. Install the water pump pulley (2) on the water pump hub (1). Install the bolts and tighten to 28 N.m (250 in.
Page 211 2010 Jeep Wrangler Sport 2010 ENGINE 3.8L - Service Information - Wrangler 22. Install the belt tensioner (6) and accessory drive belt (8). Refer to Cooling/Accessory Drive/PULLEY, Idler - Installation . Fig. 266: Hose Assembly & IAT Sensor Courtesy of CHRYSLER LLC 23.