Jeep Liberty KJ. Manual — part 914
40. Remove rocker arm and lifter assemblies from
cylinder head. Be sure to keep in same order
as removed.
41. Remove cylinder head cover/intake manifold gas-
ket from cylinder head.
42. Disconnect glow plug and engine coolant temper-
ature electrical connectors.
43. Remove turbocharger outlet to charge air cooler
hose.
44. Remove cylinder head bolts.
45. Remove cylinder head assembly from engine
block.
CLEANING
Thoroughly clean the engine cylinder head and cylinder block mating surfaces. Clean the intake and exhaust man-
ifold 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
CAUTION: The cylinder head surface and straight
edge must be absolutely clean before the flatness
measurement is taken. DO NOT check flatness
across the combustion chamber area or on the
marks left by the gasket stopper.
Use a cleaned straight edge (2) and feeler (1) gauge
to check the flatness. Lie the straight edge (2) parallel
across the cooling ports. Measure before each com-
bustion chamber toward the outer edge of the cylinder
head, above and below each combustion chamber,
between each combustion chamber, top and bottom ,
on the cylinder head and block mating surfaces. The
maximum allowed warpage is 0.1mm (0.004 in.).
9 - 1614
ENGINE - 2.8L DIESEL
KJ
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to determine cylinder head gasket thickness if one or more
cylinder liners have been replaced (Refer to 9 - ENGINE/CYLINDER HEAD - STANDARD PROCEDURE).
NOTE: If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be
used.
1. Clean and inspect gasket mating surfaces.
2. Position correct head gasket on engine block.
3. Place cylinder head on engine block.
CAUTION: New cylinder head bolts must be used. Do Not lubricate new cylinder head bolts. They already
are coated with an anti scuff treatment.
4. Tighten cylinder head bolts following procedure below.
Cylinder Head Bolt Torquing Procedure
1. Tighten all cylinder head bolts starting from the center bolts, following the cylinder head scheme and the follow-
ing sequence: 3-2-1-10-9-8-7-6-5-4-11-12-13-14-15-16-17-18.
2. Without loosening any bolts, starting from the center bolts, tighten each bolt an additional 75° in the following
sequence: 10-9-8-7-6-5-4-3-2-1.
3. Tighten the lateral cylinder head bolts an additional 50° in the following sequence: 11-12-13-14-15-16-17-18.
4. Finally tighten all bolts an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1-11-12-13-14-15-16-17-
18..
KJ
ENGINE - 2.8L DIESEL
9 - 1615
5. Slide
exhaust
manifold
and
turbocharger
on
exhaust manifold studs.
6. Install exhaust manifold retaining nuts. Tighten the
nuts to 36 N·m. in a cross sequence beginning in
the middle and working outward, then perform the
tightening sequence to the exhaust manifold nuts
again.
7. Install exhaust manifold heat shield. Torque bolts to
24.5N·m.
8. Install turbocharger outlet to charge air cooler pipe.
9. Install upper radiator hose.
10. Connect glow plug and coolant temperature sen-
sor electrical connectors.
11. Install new cylinder head cover/intake manifold
gasket.
12. Install rocker arm and lifter assemblies.Be sure to
put rocker arm and lifter assemblies in same
location as removed.
13. Install cylinder head cover/intake manifold (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
14. Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
15. Using VM.1055, install both camshaft gears and
tighten bolts finger tight.
16. Install timing belt (Refer to 9 - ENGINE/VALVE
TIMING/TIMING BELT/CHAIN AND SPROCKETS
- INSTALLATION).
17. Using VM.1055, torque cam gear retaining bolts
to 108 N·m..
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ENGINE - 2.8L DIESEL
KJ
18. Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
19. Remove crankshaft and both camshaft locking
pins at this time (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
20. Install fuel injectors (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL INJECTOR - INSTALLA-
TION).
21. Install brake booster line bracket to intake mani-
fold.
22. Install oil dip stick tube to intake manifold.
23. Connect fuel pump high pressure line to fuel rail.
24. Install fuel injector pressure lines.
25. Connect fuel return hose to fuel injectors.
26. Connect engine coolant hoses to thermostat
housing.
27. Raise vehicle.
28. Reconnect exhaust system bracket at transmis-
sion crossmember.
29. Connect exhaust stabilizer bracket to lower exhaust manifold.
30. Install turbocharger oil feed line to turbocharger.
31. Lower vehicle.
32. Install turbocharger heat shield.
33. Install exhaust manifold heat shield.
34. Install EGR cooler assembly and connect engine coolant hoses.
35. Install air cleaner housing.
36. Install main engine wiring harness and connect all ancillary electrical components.
37. Install throttle cable assembly.
38. Install viscous heater.
39. Install vibration damper.
40. Install generator (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
41. Install cooling fan support (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
42. Install front engine lift bracket.
43. Install power steering pump pulley.
44. Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L. H. Thread.
45. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
46. Install cooling fan and fan drive viscous clutch assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS-
COUS CLUTCH - INSTALLATION).
47. Install upper radiator core support.
48. Refill cooling system (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
49. Install engine cover and bracket (Refer to 9 - ENGINE COVER - INSTALLATION).
50. Connect negative battery cable.
51. Start engine and inspect for leaks (Refer to 14 - FUEL SYSTEM - WARNING).
KJ
ENGINE - 2.8L DIESEL
9 - 1617
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