Jeep Cherokee (XJ): Engine performance. Honing cylinder bores. Repair damaged or worn threads

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 4.0L engine > Service procedures > Engine performance. Honing cylinder bores. Repair damaged or worn threads

Engine performance

It is important that the vehicle is operating to its optimum performance level to maintain fuel economy and the lowest emission levels. If vehicle is not operating to these standards, refer to Engine Diagnosis outlined in this section. The following procedures can assist in achieving the proper engine diagnosis.

(1) Test cranking amperage draw. Refer to Electrical Group 8B, Cold Cranking Test.

(2) Check intake manifold bolt torque; Refer to Group 11, Exhaust System and Intake Manifold.

(3) Perform cylinder compression test. Refer to Cylinder Compression Pressure Test in the Engine Diagnosis area of this section.

(4) Clean or replace spark plugs as necessary and adjust gap as specified in Electrical Group 8D.

Tighten to specifications.

(5) Test resistance of spark plug cables. Refer to Electrical Group 8D, Spark Plug Cables.

(6) Inspect the primary wires. Test coil output voltage and primary resistance. Replace parts as necessary.

Refer to Electrical Group 8D, for specifications.

(7) Test fuel pump for pressure. Refer to Group 14, Fuel System Specifications.

(8) The air filter elements should be replaced as specified in Lubrication and Maintenance, Group 0.

(9) Inspect crankcase ventilation system as out lined in Group 0, Lubrication and Maintenance. For emission controls see Group 25, Emission Controls for service procedures.

(10) Road test vehicle as a final test.

Honing cylinder bores

Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.

(1) Used carefully, the Cylinder Bore Sizing Hone C-823 equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the required limits.

CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.

(2) Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). 20-60 strokes, depending on the bore condition, will be sufficient to provide a satisfactory surface. Using honing oil C-3501-3880 or a light honing oil available from major oil distributors.

CAUTION: DO NOT use engine or transmission oil, mineral spirits or kerosene.

(3) Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern.

The hone marks should INTERSECT at 50 to 60 for proper seating of rings (Fig. 38).

Fig. 38 Cylinder Bore Crosshatch Pattern
Fig. 38 Cylinder Bore Crosshatch Pattern


(4) A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper crosshatch angle. The number of up and down strokes per minute can be regulated to get the desired 50 to 60 angle. Faster up and down strokes increase the crosshatch angle.

(5) After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and detergent.

Dry parts thoroughly. Use a clean, white, lintfree cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.

Repair damaged or worn threads

CAUTION: Be sure that the tapped holes maintain the original center line.

Damaged or worn threads can be repaired. Essentially, this repair consists of:

  •  Drilling out worn or damaged threads.
  •  Tapping the hole with a special Heli-Coil Tap, or equivalent.
  •  Installing an insert into the tapped hole to bring the hole back to its original thread size.

    Previous pageFitting connecting rod bearings. Fitting crankshaft main bearings. Form-in-place gaskets

    Fitting connecting rod bearings INSPECTION BEARINGS Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 29) (Fig. 30). Check the bearings for normal wear patterns, scorin ...

    Next pageService engine assembly (short block). Hydrostatic lock. Engine oil service

    Service engine assembly (short block) A service replacement engine assembly (short block) may be installed whenever the original cylinder block is defective or damaged beyond repair. It consists o ...

    Other materials:

    Towing This Vehicle Behind Another Vehicle. Recreational Towing - Front-Wheel Drive (FWD) Models. Recreational Towing - 4X4 Models With 1-Speed Power Transfer Unit
    Towing This Vehicle Behind Another Vehicle   4X4 Models Towing Condition Wheels OFF the Ground Front-Wheel Drive (FWD) Models 1-Speed Power Transfer Unit 2-Speed Power Transfer Unit Flat Tow NONE NOT ALLOWED NOT ALLOWED See Instruc ...