Jeep XJ. Manual — part 313
ENGINE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 2
MECHANICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TAPPET NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
ENGINE MOUNTS — LHD DIESEL . . . . . . . . . . 13
ENGINE MOUNTS — RHD DIESEL . . . . . . . . . . 15
2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . 18
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 22
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 23
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 23
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 24
VALVE SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . . 25
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 30
TIMING GEAR COVER OIL SEAL . . . . . . . . . . . . 30
TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . 30
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CAMSHAFT BEARINGS. . . . . . . . . . . . . . . . . . . . 32
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INTERNAL VACUUM PUMP . . . . . . . . . . . . . . . . 33
OIL PUMP PRESSURE RELIEF VALVE . . . . . . . . 34
OIL FILTER ADAPTER AND ENGINE OIL
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CYLINDER WALL LINER ASSEMBLY . . . . . . . . . 38
CRANKSHAFT MAIN BEARINGS. . . . . . . . . . . . . 40
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 43
CLEANING AND INSPECTION
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 43
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 43
PISTONS AND CONNECTING ROD
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CYLINDER WALL LINER ASSEMBLY . . . . . . . . . 45
OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . 46
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 48
SPECIAL TOOLS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 49
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
DESCRIPTION
The engine model code and serial number are
stamped on the left side of the engine block, just
below the oil dipstick tube (Fig. 1). The engine code
on the XJ 2.5L is DD85C followed by a 5 digit serial
number.
Fig. 1 Engine Code Location
XJ
ENGINE
9 - 1
2000 JEEP CHEROKEE
DIAGNOSIS AND TESTING
SERVICE DIAGNOSIS—DIESEL—
PERFORMANCE
CONDITION
POSSIBLE CAUSES
CORRECTION
ENGINE WILL NOT CRANK
OR CRANKS SLOWLY
1. Starting motor operating, but not
cranking the engine.
1. Remove the starter motor. Check for
broken flywheel teeth or a broken
starting motor spring.
2. Crankshaft rotation restricted.
2. Rotate the engine to check for
rotational resistance.
3. Starting circuit connections loose or
corroded.
3. Clean and tighten connections.
4. Neutral safety switch or starter relay
inoperative.
4. Check starter relay supply voltage
and proper operation of neutral safety
switch (if equipped). Replace defective
parts.
5. Battery charge low.
5. Check battery voltage. Replace
battery if a charge cannot be held.
Displacement . . . . . . . . 2.5L (2499 cc)
Bore . . . . . . . . . . . . . . . 92.00
Stroke . . . . . . . . . . . . . . 94.00
Compression Ratio . . . . 21:1
Vacuum at idle . . . . . . . 600 mm/Hg (23.6 In/Hg)
Belt Tension . . . . . . . . . 400/500 N Automatic
Tensioner
Thermostat Opening . . . 80°C
6 2°C
Generator Rating . . . . . Denso 12V—95A
Cooling System Capacity. 9.5 Liter
P/S Capacity . . . . . . . . . 0.75 Liter
Engine Oil Capacity . . . 7.2L w/filter change
Timing System . . . . . . . Pushrod operated overhead
valves, with gear-driven
camshaft in crankcase.
Air Intake . . . . . . . . . . . Dry filter.
Fuel Feed . . . . . . . . . . . Vane pump incorporated in
injection pump.
Fuel System . . . . . . . . . Indirect fuel injection
(precumbustion chamber).
Combustion Cycle . . . . . 4 stroke
Cooling System . . . . . . . Water cooling.
Injection Pump . . . . . . . Rotary pump and
electronically managed.
Lubrication . . . . . . . . . . Pressure lubrication by
rotary pump, full-flow
filtration.
Engine Rotation . . . . . . . Clockwise viewed from
front cover.
Engine Description
9 - 2
ENGINE
XJ
DIAGNOSIS AND TESTING (Continued)
2000 JEEP CHEROKEE
CONDITION
POSSIBLE CAUSES
CORRECTION
6. No voltage to starter solenoid.
6. Check voltage to solenoid. If
necessary, replace the solenoid.
7. Solenoid or starter motor
inoperative.
7. Replace starter motor.
ENGINE CRANKS, BUT WILL
NOT START NO SMOKE
1. No fuel in supply tank.
1. Fill fuel supply.
2. Electrical fuel shutdown solenoid not
operating.
2. Check for loose wires and verify that
the fuel shutdown solenoid and fuel
shutdown solenoid relay is functioning.
3. Exhaust plugged.
3. Remove the obstruction.
4. Fuel filter plugged.
4. Drain fuel/water separator and
replace fuel filter.
5. Excessive fuel inlet restriction.
5. Check fuel inlet restriction. Correct
cause.
6. Injection pump not getting fuel or
fuel is aerated.
6. Check fuel flow/bleed fuel system.
7. Worn or inoperative injection pump.
7. Visually check delivery with
externally connected injector to one of
the pump outlets. Repair or replace the
pump if fuel is not being delivered.
ENGINE HARD TO START,
OR WILL NOT START
SMOKE FROM EXHAUST
1. Incorrect starting procedure.
1. The fuel shutoff solenoid control
must be in the run position. Ensure
proper procedure is being used.
2. Cranking speed too slow.
2. (A) Verify that the transmission is not
engaged.
(B) Check the battery, starting motor
and look for loose or corroded wiring
connections.
3. Cylinder heads heater plugs relay
defective.
3. Verify system is working. Repair/
replace inoperative parts.
4. One or more cylinder head heater
plugs defective.
4. Verify system is working. Repair/
replace inoperative parts.
5. Insufficient intake air.
5. Inspect or replace filter and check
for obstruction to the air supply tube.
XJ
ENGINE
9 - 3
DIAGNOSIS AND TESTING (Continued)
2000 JEEP CHEROKEE
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