Jeep XJ. Manual — part 331
(5) Position the turbocharger oil pressure supply
line in its original position (Fig. 18). Torque the turbo
fitting to 27 N·m (20 ft. lbs.).
(6) Install the exhaust manifold heatshield (Fig.
19). Torque bolts to 11 N·m (97 in. lbs.).
(7) Install the EGR tube on the exhaust manifold.
Leave loose at this time.
(8) Raise the vehicle on a hoist.
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(9) Slide the exhaust downpipe heatshield up over
the pipe and strap it in its original position (Fig. 20).
(10) Install the steering shaft. Torque the pinch
bolt to 49 N·m (36 ft. lbs.).
(11) Install the turbocharger oil return hose on the
engine block (Fig. 21).
(12) Install the exhaust system support clamp
(Fig. 22). Torque nuts to 23 N·m (17 ft. lbs.).
(13) Connect the exhaust system at the (3) bolt
flange (Fig. 22). Torque the bolts to 23 N·m (17 ft.
lbs.).
(14) Lower the vehicle on hoist.
(15) Install the clutch master cylinder through the
bulkhead.
Fig. 17 Turbocharger / Exhaust Manifold Assembly
1 – OIL RETURN LINE
2 – WASTEGATE VACUUM SUPPLY HOSE
3 – TURBO TO EXHAUST MANIFOLD RETAINING NUTS
4 – BENCH VISE
5 – TURBOCHARGER ASSEMBLY (REMOVED FROM VEHICLE)
6 – WASTEGATE VACUUM ACTUATOR
Fig. 18 R. H. D. Turbo Position & Orientation
1 – CLUTCH MASTER CYLINDER
2 – EXHAUST DOWNPIPE HEATSHIELD
3 – TURBOCHARGER OIL PRESSURE SUPPLY LINE AT TURBO
4 – TURBOCHARGER OIL PRESSURE SUPPLY LINE AT ENGINE
BLOCK
5 – ACTUATOR VACUUM SUPPLY
6 – TURBOCHARGER WASTEGATE ACTUATOR
Fig. 19 2.5L Turbo Diesel — Heatshields
1 – CLUTCH MASTER CYLINDER HEATSHIELD
2 – TURBO OIL PRESSURE SUPPLY LINE
3 – TURBOCHARGER
4 – EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS
11 - 8
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(16) Working from the inside of the vehicle, Install
the (2) clutch master cylinder retaining nuts.
(17) Connect the neutral safety switch at the
clutch pedal.
(18) Install the Knee Blocker. Refer to Group 8E,
Instrument Panel Systems for procedure.
(19) Install the clutch master cylinder heatshield.
(20) Install the intake manifold elbow and the
EGR valve as an assembly. Torque the intake elbow
bolts to 11 N·m (97 in.lbs.).
(21) Install the (2) bolts holding the EGR tube to
the EGR valve. Torque to bolts 27 N·m (20 ft. lbs.).
(22) Torque the EGR tube on the exhaust manifold
to 28 N·m (21 ft. lbs.).
(23) Install the innercooler inlet and outlet hoses
on the engine.
(24) Install the EGR vacuum supply hose on the
EGR valve.
(25) Install the air filter cover and outlet hose on
the turbocharger.
(26) Connect the breather hose on the air cleaner
outlet hose.
(27) Install the heater core coolant supply and the
brake vacuum supply lines in there original position.
(28) Connect the negative battery cable
(29) Fill the cooling system. Refer to Group 7,
Cooling System for the procedure.
(30) Start the engine and check for leaks.
Fig. 20 Exhaust Downpipe Heatshield
1 – EXHAUST MANIFOLD DOWNPIPE HEATSHIELD RETAINING
STRAPS
Fig. 21 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
Fig. 22 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 9
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
INTAKE MANIFOLD
REMOVAL
(1) Remove exhaust manifold and turbocharger
assembly.
(2) Remove water manifold.
(3) Remove intake manifold.
CLEANING
Clean the intake manifold and cylinder head mat-
ing surfaces. DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) Install the new intake manifold gasket.
(2) Position the intake manifold in place and fin-
ger tighten the mounting nuts.
(3) Tighten the fasteners in sequence and to the
specified torque 30 N·m.
(4) Position the water manifold in place and finger
tighten the mounting nuts.
(5) Tighten the fasteners to the specified torque 12
N·m.
(6) Install
exhaust
manifold
and
turbocharger
assembly.
(7) Install charge air cooler hose to intake mani-
fold.
(8) Connect the battery negative cable.
(9) Start engine and check for leaks.
SPECIFICATIONS
TORQUE SPECIFICATIONS
Description
Torque
EGR
Attaching Bolts . . . . . . . . . . . . . . . . . . . . . . 27N·m
EGR
Tube Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N·m
EGR
Tube Flange Bolts . . . . . . . . . . . . . . . . . . . . 27 N·m
Exhaust Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N·m
Exhaust Manifold
Heat Shield Bolts . . . . . . . . . . . . . . . . . . . . 11 N·m
Exhaust Pipe
Support Clamp Bolts . . . . . . . . . . . . . . . . 22.5 N·m
Exhaust Pipe
Support Clamp Screw . . . . . . . . . . . . . . . . 22.5 N·m
Intake Elbow to Intake Manifold
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N·m
Intake Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N·m
Muffler-to-Exhaust Pipe
Clamp Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 43 N·m
Tail Pipe Clamp
Hanger bolt . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
Turbocharger-to-Exhaust manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N·m
Turbocharger
Oil Feed Line . . . . . . . . . . . . . . . . . . . . . . 27.4 N·m
Turbocharger Down Pipe-to-Exhaust Pipe
Bolts/Nuts . . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
Turbocharger Down Pipe-to-Turbocharger
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m
11 - 10
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
FRAME AND BUMPERS
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . 1
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
TABLE OF CONTENTS
page
DESCRIPTION AND OPERATION
FRAME AND BUMPERS. . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
FRAME AND BUMPERS
FRAME
DESCRIPTION
Jeep Cherokee vehicles do not have a conventional
frame. They are constructed as a unitized body and
frame. Jeep unibodies are constructed from special
high strength steel and coated metals. This process
reduces weight and provides strength to withstand
the forces applied against structural members. The
structural members provide a unibody that has great
structural strength.
BUMPERS
DESCRIPTION
The bumpers on the Jeep Cherokee are made up of
the main bumper beam, the end caps, air deflector
(front bumper) and mounting brackets. Some Chero-
kee models also have a tow hook support bracket.
OPERATION
The bumpers are fastened to the unitized body
frame rails. The bumper end caps are fastened to the
bumper and the body side sheet metal.
XJ
FRAME AND BUMPERS
13 - 1
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