Jeep Cherokee (XJ): Exhaust manifold. Cylinder head cover. Rocker arms and push rods

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 2.5L engine > Removal and installation > Exhaust manifold. Cylinder head cover. Rocker arms and push rods

Exhaust manifold

REMOVAL

(1) Disconnect the battery negative cable.

(2) Raise the vehicle.

(3) Disconnect the exhaust pipe from the engine exhaust manifold.

(4) Lower the vehicle.

(5) Remove intake manifold (refer to procedure in this section) (6) Remove fasteners 2 through 5 and remove the intake manifold (Fig. 51).

(7) Remove fasteners 1, 6 and 7 and remove the engine exhaust manifold (Fig. 51).

INSTALLATION

(1) Clean the intake and engine exhaust manifolds and cylinder head mating surfaces. DO NOT allow foreign material to enter either the intake manifold or the ports in the cylinder head.

(2) Install a new intake manifold gasket over the alignment dowels on the cylinder head.

(3) Install the engine exhaust manifold assembly.

Exhaust manifold must be centrally located over the end studs and spacer (Fig. 51).

(4) Tighten bolt No.1 to 41 N·m (30 ft. lbs.) torque (Fig. 51).

(5) Install the intake manifold on the cylinder head dowels (Fig. 51).

Fig. 51 Intake/Exhaust Manifold Removal/Installation-2.5L Engine
Fig. 51 Intake/Exhaust Manifold Removal/Installation-2.5L Engine

(6) Install bolts 2 through 5 (Fig. 51). Tighten these bolts to 31 N·m (23 ft. lbs.) torque.

(7) Install new engine exhaust manifold spacers over the engine exhaust manifold mounting studs in the cylinder head (Fig. 51).

(8) Tighten nuts 6 and 7 to 23 N·m (17 ft. lbs.) torque (Fig. 51).

(9) Install all components to the intake manifold.

(10) Raise the vehicle.

(11) Connect the exhaust pipe to the engine exhaust manifold. Tighten the bolts to 31 N·m (23 ft.

lbs.) torque.

(12) Lower the vehicle.

(13) Connect the battery negative cable.

(14) Start the engine and check for leaks.

Cylinder head cover

A cured gasket is part of the engine cylinder head cover.

REMOVAL

(1) Disconnect negative cable from battery.

(2) Disconnect the Crankcase Ventilation (CCV) vacuum hose from engine cylinder head cover (Fig.

52).

(3) Remove the air inlet hose and resonator from the air cleaner and throttle body.

(4) Remove the engine cylinder head cover mounting bolts.

(5) Remove the engine cylinder head cover (Fig.

52).

(6) Remove any original sealer from the cover sealing surface of the engine cylinder head and clean the surface using a fabric cleaner.

(7) Remove all residue from the sealing surface using a clean, dry cloth.

Fig. 52 Engine Cylinder Head Cover
Fig. 52 Engine Cylinder Head Cover

1 - AIR INLET FITTING
2 - AIR FILTER COVER
3 - FIXED ORIFICE FITTING

INSTALLATION

(1) Inspect the engine cylinder head cover for cracks. Replace the cover, if cracked.

NOTE: The original dark grey gasket material should NOT be removed. If sections of the gasket material are missing or are compressed, replace the engine cylinder head cover. However, sections with minor damage such as small cracks, cuts or chips may be repaired with a hand held applicator. The new material must be smoothed over to maintain gasket height. Allow the gasket material to cure prior to engine cylinder head cover installation.

(2) If a replacement cover is installed, transfer the CCV valve grommet the oil filler cap from the original cover to the replacement cover.

(3) Install engine cylinder head cover. Tighten the mounting bolts to 13 N·m (115 in. lbs.) torque.

(4) Connect the CCV hoses (Fig. 52).

(5) Connect negative cable to battery.

(6) Install the air inlet hose and resonator.

Rocker arms and push rods

This procedure can be done with the engine in or out of the vehicle.

REMOVAL

(1) Remove the engine cylinder head cover. (Refer to procedure in this section) (2) Check for rocker arm bridges which are causing misalignment of the rocker arm to valve tip area.

(3) Remove the capscrews at each bridge and pivot assembly (Fig. 53). Alternately loosen the capscrews one turn at a time to avoid damaging the bridges.

(4) Remove the bridges, pivots and corresponding pairs of rocker arms (Fig. 53). Place them on a bench in the same order as removed.

(5) Remove the push rods and place them on a bench in the same order as removed.

Fig. 53 Rocker Arm Assembly
Fig. 53 Rocker Arm Assembly

1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS

(6) Clean all the components with cleaning solvent.

(7) Use compressed air to blow out the oil passages in the rocker arms and push rods.

INSTALLATION

(1) Lubricate the ball ends of the push rods with Mopar Engine Oil Supplement, or equivalent and install push rods in their original locations. Ensure that the bottom end of each push rod is centered in the tappet plunger cap seat.

(2) Using Mopar Engine Oil Supplement, or equivalent, lubricate the area of the rocker arm that the pivot contacts. Install rocker arms, pivots and bridge above each cylinder in their original position.

(3) Loosely install the capscrews through each bridge.

(4) At each bridge, tighten the capscrews alternately, one turn at a time, to avoid damaging the bridge. Tighten the capscrews to 28 N·m (21 ft. lbs.) torque.

(5) Install the engine cylinder head cover.

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