Jeep XJ. Manual — part 323
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine from vehicle. Refer to
engine removal and installation in this section.
(3) Install the engine on an engine stand.
(4) Remove the accessary drive system.
(5) Remove the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
(6) Remove the rocker arm assemblies and push
rods. Refer to rocker arm and push rod removal and
installation in this section.
(7) Remove the intake manifold, exhaust manifold
and turbocharger. Refer to Group 11, Exhaust Sys-
tem and Turbocharger.
(8) Remove the water manifold.
(9) Remove the oil feed lines to rocker arms.
(10) Remove the cylinder heads. Refer to cylinder
head removal and installation in this section.
(11) Remove the oil pan and oil pick-up.
(12) Remove the pistons and connecting rods.
(13) Remove the vibration damper. Refer to vibra-
tion damper removal and installation in this section.
(14) Remove the timing gear cover. Refer to timing
gear cover removal and installation in this section.
(15) Remove the oil pump and vacuum pump from
block.
(16) Install special tool VM.1004 onto crankshaft
over gear (Fig. 66).
(17) Remove the main bearing oil feed and crank-
shaft carrier locators from block.
(18) Remove the flywheel and adaptor plate from
engine block.
(19) Remove the thrust bearings from rear main
bearing carrier.
(20) Slide the crankshaft and bearing carriers
rearward to rear of block. If you encounter difficulty
in removing the complete assembly as previously
described, slide the assembly rearward sufficiently to
gain access to the main bearing carrier bolts. Mark
Fig. 65 Crankshaft and Bearing Assembly
Fig. 64 Liner Clamp Location
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
the carriers for assembly and remove the bolts, two
for each carrier (Fig. 67).
(21) Separate the two halves of each carrier,
remove from the crankshaft and temporarily re-as-
semble the carriers (Fig. 68). Withdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
(1) Fit the main bearing supports together. Torque
to 44 N·m (32 ft. lbs.)
(2) Check internal diameter of bearings.
(3) If internal diameter of original bearing is being
checked and figures are not within specifications,
new bearings must be used.
(4) Check the crankshaft main bearing journals to
bearing clearances. Clearances of main bearings is.03
to.088mm (.0011 to.0035 in.).
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed air
before assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(5) Thoroughly clean crankcase and oil passages,
and blow dry with compressed air.
(6) Install new main bearing shells in each of the
carrier halves. Assemble the carriers to the crank-
shaft
journals,
ensuring
that
the
carriers
are
installed in their original locations and that the pis-
ton jet notch is towards the front of the crank-
shaft. Secure each carrier with the two bolts
tightening evenly to 44 N·m (32 ft. lbs.). Check that
the oil jet is in position (Fig. 68).
(7) Slide special tool VM.1004 over the crankshaft
gear and, insert the crankshaft and carrier assembly
into the crankcase in the same manner used for
removal.
(8) Align the holes in the lower supports, with the
center of the crankcase webs (Fig. 69).
(9) Secure each support assembly to the crankcase
with the main bearing oil feed and support locators.
Torque to 54 N·m (40 ft. lbs).
(10) Install the rear main bearing support onto
crankshaft ensuring arrow on bearing support aligns
with vertical web in center of crankcase.
Fig. 66 Crankshaft Special Tool VM.1004
1 – TOOL
Fig. 67 Crankshaft Support Locator Bolts
Fig. 68 Crankshaft and Carrier Bearing Assembly
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ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(11) Install the rear oil seal.
(12) Install the new O-rings in adaptor plate.
(13) Install the adaptor plate to block. Torque nuts
to 26.5 N·m (20 ft. lbs.).
(14) Install the Allen bolts through adaptor plate
to rear main bearing support. Torque to 11 N·m (97
in. lbs.).
(15) Position the flywheel and O-ring on crank-
shaft and align bolt holes.
NOTE: For purposes of checking crankshaft end
play, used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(16) Install 2 flywheel bolts, 180° apart, and
tighten bolts to 20 N·m plus 60° (15 ft. lbs.) plus 60°.
(17) Attach dial indicator to engine block.
(18) Move crankshaft toward front of engine and
zero indicator.
(19) Move crankshaft toward the rear of engine
and record measurement.
(20) Subtract specified crankshaft end play from
figure obtained. Crankshaft end play.153 to.304mm
(.0060 to.0119 in.).
(21) Select thrust washers which will give correct
end play.
(22) Remove tools and flywheel.
(23) Lubricate thrust washer halves and fit them
into the rear main bearing carrier.
(24) Ensure that crankshaft end and flywheel mat-
ing surfaces are clean and dry. Install “O” ring in fly-
wheel groove.
(25) To verify correct end play, install 2 flywheel
bolts 180° apart, and tighten bolts to 20 N·m plus 60°
(15 ft. lbs. plus 60°).
(26) Measure crankshaft end play with a dial
gauge. Crankshaft end play should not exceed.153
to.304mm (.0060 to.0119 in.) (Fig. 70).
CAUTION: Use NEW flywheel bolts for the following
procedure.
(27) Install a new O-ring on flywheel. Install fly-
wheel on crankshaft. The 6 flywheel bolts must be
tightened as follows:
a. Lubricate and install the 6 new flywheel bolts.
b. Torque the 6 flywheel bolts to 49 N·m (36 ft.
lbs.) starting one bolt and following with the opposite
one (cross tightening) until completion, in a clockwise
direction..
c. Loosen one bolt at a time and tighten to 19.6
N·m (14 ft. lbs.) plus 75° using the cross tightening
method.
(28) Install the pistons and connecting rod assem-
blies. Refer to piston and connecting rods removal
and installation in this section.
(29) Install the oil pick up tube. Torque bolts to 25
N·m (18 ft. lbs.).
(30) Install the oil pan. Refer to oil pan removal
and installation in this section.
(31) Install the vacuum pump, being careful to
align the gear timing marks with those on the crank-
shaft gear. Torque screws to 20 N·m (15 ft. lbs.).
(32) Before installing the oil pump check pump
bore depth in block (A) and pump body height (B)
(Fig. 71). Difference between A and B should be
0.020-0.082 mm (.0007 to 0032 in.).
(33) Install the oil pump. Torque screws to 27 N·M
(20 ft.lbs.). Check for normal backlash between pump
and crankshaft gears.
(34) Install the timing gear cover. Refer to timing
gear cover removal and installation in this section.
Fig. 69 Main Bearing Support Alignment
Fig. 70 Measuring Crankshaft End Play
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(35) Install the vibration damper. Refer to vibra-
tion damper removal and installation in this section.
(36) Install the cylinder heads. Refer to cylinder
head removal and installation in this section.
(37) Install the rocker arms and push rods. Refer
to rocker arm and push rod removal and installation
in this section.
(38) Install the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
(39) Install the accessary drive system.
(40) Install the engine in vehicle. Refer to engine
removal and installation in this section.
(41) Fill engine with the correct amount of fluids
specified.
(42) Connect the negativre battery cable.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE
(1) Pry out plunger retainer spring clip.
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring. Check valve could be
flat or ball.
ASSEMBLE
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser-
vice with new assemblies.
(3) If plunger shows signs of scoring or wear,
install a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat-
ing, install a new tappet assembly.
(4) Assemble tappets.
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces (Fig. 72).
Minimum cylinder head thickness 89.95mm (3.541
in.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary
to
machine
the
remaining
cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
ROCKER ARMS AND PUSH RODS
CLEANING
Clean all the components (Fig. 73) with cleaning
solvent.
Fig. 71 Oil Pump Bore Depth
Fig. 72 Checking Cylinder Head Flatness
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
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