Jeep XJ. Manual — part 319
INSTALLATION
(1) Lubricate the tappets.
(2) Install the tappets and retainers in their origi-
nal positions. Ensure that the oil feed hole in the
side of the tappet body faces up (away from the
crankshaft).
(3) Install the cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head removal
and installation in this section.
(4) Install the push rods.
(5) Install the rocker arms. Refer to rocker arms
and push rod removal and installation in this section.
(6) Install the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
(7) Connect the negative battery cable.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
(8) Start and operate engine. Warm up to normal
operating temperature.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Disconnect the negative battery cable.
(2) Discharge
the
air
conditioning
system,
if
equipped. Refer to Group 24, Heating and Air Condi-
tioning for procedure.
(3) If equipped with air conditioning, remove the
service valves and cap the compressor ports. Refer to
Group 24, Heating and Air Conditioning.
(4) Remove the generator bracket.
(5) Remove the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
(6) Remove the rocker arm retaining nut (Fig. 27).
(7) Remove the rocker assembly. Place them on a
bench in the same order as removed.
(8) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
WARNING: During the installation of the rocker arm
assemblies it is possible to cause valve interfer-
ence between the piston and valve if the piston is
near Top Dead Center (TDC). This is due to the slow
bleed down rate of the tappets when adjusting the
rocker arm assemblies. Follow the procedure below
to ensure that engine damage does not occur.
• Install the rocker arm assemblies in the same
order as removed.
• Bring piston # 1 to Top Dead Center.
• Rotate the engine 40° counter clockwise and
stop.
• At this point tighten all of the rocker arm nuts.
Torque nuts to 27 N·m (20 ft. lbs.).
NOTE: You must allow 30 minutes before starting
the engine once the rocker arms are torqued. This
will allow the hydraulic tappets to stabilize and pre-
vent the possibility of piston to valve contact.
(2) Install the cylinder head cover. Refer to cylin-
der head cover removal and installation in this
group.
(3) Evacuate and charge the air conditioning sys-
tem. Refer to Group 24, Heater and Air Conditioning.
(4) Connect the negative battery cable.
VALVE SPRINGS
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
(1) Disconnect the negative battery cable.
Each valve spring is held in place by a retainer
and a set of conical valve locks. The locks can be
removed only by compressing the valve spring.
(2) Remove the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
Fig. 27 Rocker Arm Retaining Nut
1 – ROCKER ARM ASSEMBLY
2 – ROCKER ARM RETAINING NUTS
3 – ROCKER ARM SPRING PLATE
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ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(3) Remove the rocker arms assemblies and push
rods. Refer to rocker arm and push rod removal and
installation in this section. Retain the push rods, and
rocker arms assemblies in the same order and posi-
tion as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Install an air hose adaptor in the fuel injector
hole.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool to compress the spring and remove
the locks.
(8) Remove the valve spring and retainer.
(9) Inspect the valve stems, especially the grooves.
An Arkansas smooth stone should be used to remove
nicks and high spots.
INSTALLATION
(1) Install the valve spring and retainer.
(2) Compress the valve spring with Valve Spring
Compressor Tool and insert the valve locks. Release
the spring tension and remove the tool. Tap the
spring from side-to-side to ensure that the spring is
seated properly on the engine cylinder head.
(3) Disconnect the air hose. Remove the adaptor
from the fuel injector hole and install the fuel injec-
tor.
(4) Repeat the procedures for each remaining valve
spring to be removed.
(5) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.
(6) Install the rocker arm assemblies, in their orig-
inal locations. Torque nuts to 29.4 N·m (264 in. lbs.).
(7) Install the cylinder head cover. Refer to cylin-
der head cover removal and installation in this sec-
tion.
(8) Connect the negative battery cable.
ENGINE CYLINDER HEAD
REMOVAL
(1) Disconnect the negative battery cable.
WARNING: DO
NOT
REMOVE
THE
CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(3) Discharge
the
air
conditioning
system,
if
equipped. Refer to Group 24, Heating and Air Condi-
tioning for procedure.
(4) If equipped with air conditioning, remove the
A/C lines at the compressor and cap. Refer to Group
24, Heating and Air Conditioning. Remove A/C line
bracket attached to cylinder head cover, and move
A/C lines away from cylinder head.
(5) Remove the air cleaner hose from turbocharger
and breather hose.
(6) Remove the air cleaner assembly and breather
hose.
(7) Remove the generator support bracket.
(8) Remove the upper radiator hose and coolant
recovery hose.
(9) Remove the water manifold and recovery hose.
(10) Disconnect
the
heater
hoses
and
coolant
recover bottle hose.
(11) Disconnect the EGR tube from EGR valve.
(12) Remove the EGR valve
(13) Remove the exhaust heat shield from exhaust
manifold.
(14) Remove the exhaust heat shield from down
pipe.
(15) Remove the exhaust down pipe from turbo-
charger (Fig. 28).
(16) Disconnect the oil feed line from turbocharger.
Fig. 28 Turbocharger
1 – EGR TUBE
2 – EGR VALVE
3 – OIL FEED LINE
4 – OIL DRAIN
5 – TURBO
XJ
ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(17) Disconnect the oil drain line from turbo-
charger.
(18) Remove the Exhaust manifold. Refer to Group
11, Exhaust System and Turbocharger.
(19) Remove the Intake manifold. Refer to intake
manifold removal and installation procedure in this
section.
(20) Remove the oil feed line retaining bracket at
rear of #4 cylinder head.
(21) Remove the oil feed line retaining bracket
(Fig. 29).
(22) Remove the oil feed line for rocker arm
assemblies (Fig. 30).
(23) Remove the Crankcase breather hose from
rear of the valve cover
(24) Remove the injector sensor wire and the glow
plug hot lead.
(25) Remove the fuel lines and fuel filter. Refer to
Group 14, Fuel Systems for procedure.
(26) Remove the injector fuel lines from injectors
to pump.
(27) Remove the fuel injectors with tool VM.1012
(Fig. 31). Refer to Group 14, Fuel System for proce-
dure.
(28) Remove the engine cylinder head cover.
(29) Remove the rocker retaining nuts (Fig. 33).
(30) Remove the rocker arm assemblies. Place
them on a bench in the same order as removed.
(31) Remove the push rods and place them on a
bench in the same order as removed.
(32) Mark the cylinder head positions.
(33) Remove the engine cylinder head bolts with
special tool VM.1018 and VM.1019.
(34) Remove the engine cylinder head and gasket.
(35) Stuff clean lint free shop towels into the cyl-
inder bores.
CYLINDER HEAD GASKETS
A steel cylinder head gasket is used for all four cyl-
inder heads.
Cylinder head gaskets are available in three thick-
nesses. Identification holes in the right front corner
of the gasket indicate the thickness of the gasket
(Fig. 34).
Fig. 29 Oil Feed Line Retainer
1 – CYLINDER HEAD OIL SUPPLY LINE RETAINING CLIP
2 – EXHAUST MANIFOLD
3 – CYLINDER HEAD OIL SUPPLY LINE
4 – REAR OF CYLINDER HEADS
5 – CYLINDER HEAD COVER
Fig. 30 Rocker Arm Oil Feed Lines
Fig. 31 Fuel Injector Tool VM.1012B
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ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
CAUTION: Piston protrusion must be measured, to
determine cylinder head gasket thickness, if one or
more cylinder wall liners have been replaced.
NOTE: If
cylinder
wall
liners
have
not
been
removed; the same thickness head gasket removed,
may be used.
MEASURING PISTON PROTRUSION
(1) Use special tool VM.1010 with dial indicator
special tool VM.1013 (Fig. 35).
(2) Bring the piston of cylinder no. 1 exactly to top
dead center.
(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
Fig. 32 Fuel Injector
Fig. 33 Rocker Arm Retaining Nuts
1 – ROCKER ARM ASSEMBLY
2 – ROCKER ARM RETAINING NUTS
3 – ROCKER ARM SPRING PLATE
Fig. 34 Steel Type Cylinder Head Gasket—
identification
HOW TO IDENTIFY GASKET THICKNESS
NO HOLES . . . . . . . . . . . .
1.41mm
2 HOLES . . . . . . . . . . . . .
1.51mm
1 HOLE . . . . . . . . . . . . . .
1.61mm
Fig. 35 Measuring Piston Protrusion
XJ
ENGINE
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REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
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