Jeep Cherokee (XJ): Oil pump. Piston and connecting rod. Rear main oil seal

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 2.5L engine > Removal and installation > Oil pump. Piston and connecting rod. Rear main oil seal

Oil pump

The positive-displacement gear-type oil pump is driven by the distributor shaft, which is driven by a gear on the camshaft. Oil is siphoned into the pump through an inlet tube and strainer assembly that is pressed into the pump body.

The pump incorporates a nonadjustable pressure relief valve to limit maximum pressure to 517 kPa (75 psi). In the relief position, the valve permits oil to bypass through a passage in the pump body to the inlet side of the pump.

Oil pump removal or replacement will not affect the distributor timing because the distributor drive gear remains in mesh with the camshaft gear.

REMOVAL

(1) Drain the engine oil.

(2) Remove the oil pan.

(3) Remove the pump-to-cylinder block attaching bolts. Remove the pump assembly with gasket (Fig.

84).

CAUTION: If the oil pump is not to be serviced, DO NOT disturb position of oil inlet tube and strainer assembly in pump body. If the tube is moved within the pump body, a replacement tube and strainer assembly must be installed to assure an airtight seal.

Fig. 84 Oil Pump Assembly
Fig. 84 Oil Pump Assembly

1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS

INSTALLATION

(1) Install the oil pump on the cylinder block using a replacement gasket. Tighten the bolts to 23 N·m (17 ft. lbs.) torque.

(2) Install the oil pan and gasket.

(3) Fill the oil pan with oil to the specified level.

Piston and connecting rod

REMOVAL

(1) Remove the engine cylinder head cover.

(2) Remove the rocker arms, bridges and pivots.

(3) Remove the push rods.

(4) Remove the engine cylinder head.

(5) Position the pistons one at a time near the bottom of the stroke. Use a ridge reamer to remove the ridge from the top end of the cylinder walls. Use a protective cloth to collect the cuttings.

(6) Raise the vehicle.

(7) Drain the engine oil.

(8) Remove the oil pan and gasket.

(9) Remove the connecting rod bearing caps and inserts. Mark the caps and rods with the cylinder bore location. The connecting rods and caps are stamped with a two letter combination (Fig. 85).

Fig. 85 Stamped Connecting Rods and Caps
Fig. 85 Stamped Connecting Rods and Caps

1 - CONNECTING ROD CAP
2 - CONNECTING ROD

(10) Lower the vehicle until it is about 2 feet from the floor.

CAUTION: Ensure that the connecting rod bolts DO NOT scratch the crankshaft journals or cylinder walls. Short pieces of rubber hose, slipped over the rod bolts will provide protection during removal.

(11) Have an assistant push the piston and connecting rod assemblies up and through the top of the cylinder bores (Fig. 86).

Fig. 86 Removal of Connecting Rod and Piston Assembly
Fig. 86 Removal of Connecting Rod and Piston Assembly

1 - PISTON
2 - CONNECTING ROD
3 - CYLINDER BLOCK

INSTALLATION

(1) Clean the cylinder bores thoroughly. Apply a light film of clean engine oil to the bores with a clean lint-free cloth.

(2) Install the piston rings on the pistons if removed.

(3) Lubricate the piston and rings with clean engine oil.

CAUTION: Ensure that connecting rod bolts do not scratch the crankshaft journals or cylinder walls.

Short pieces of rubber hose slipped over the connecting rod bolts will provide protection during installation.

(5) Use a piston ring compressor to install the connecting rod and piston assemblies through the top of the cylinder bores (Fig. 87).

(6) Ensure the arrow on the piston top points to the front of the engine (Fig. 87).

(7) Raise the vehicle.

(8) Each bearing insert is fitted to its respective journal to obtain the specified clearance between the bearing and the journal. In production, the select fit is obtained by using various-sized, color-coded bearing inserts as listed in the Connecting Rod Bearing Fitting Chart. The color code appears on the edge of the bearing insert. The size is not stamped on inserts used for production of engines.

Fig. 87 Rod and Piston Assembly Installation
Fig. 87 Rod and Piston Assembly Installation

(9) The rod journal is identified during the engine production by a color-coded paint mark on the adjacent cheek or counterweight toward the flange (rear) end of the crankshaft. The color codes used to indicate journal sizes are listed in the Connecting Rod Bearing Fitting Chart.

(10) When required, upper and lower bearing inserts of different sizes may be used as a pair (refer to Connecting Rod Bearing Fitting Chart). A standard size insert is sometimes used in combination with a 0.025 mm (0.001 inch) undersize insert to reduce clearance 0.013 mm (0.0005 inch).

CAUTION: DO NOT intermix bearing caps. Each connecting rod and bearing cap are stamped with the cylinder number. The stamp is located on a machined surface adjacent to the oil squirt hole that faces the camshaft side of the cylinder block.

(11) Install the connecting rod bearing caps and inserts in the same positions as removed.

CAUTION: Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pistons face the front of the engine.

(13) Install the oil pan and gaskets as outlined in the installation procedure.

(14) Lower the vehicle.

(15) Install the engine cylinder head, push rods, rocker arms, bridges, pivots and engine cylinder head cover.

(16) Fill the crankcase with engine oil.

Rear main oil seal

REMOVAL

(1) Remove the flywheel or converter drive plate.

Discard the old bolts.

(2) Pry out the seal from around the crankshaft flange, making sure not to scratch or nick the crankshaft.

(Fig. 88).

Fig. 88 Replacement of Rear Crankshaft Oil Seal
Fig. 88 Replacement of Rear Crankshaft Oil Seal

1 - CRANKSHAFT
2 - CRANKSHAFT OIL SEAL

INSTALLATION

(1) Wipe the seal surface area of the crankshaft until it is clean.

(2) Coat the outer lip of the replacement rear main bearing seal with engine oil.

(3) Carefully position the seal into place. Use rear main Seal Installer Tool 6271A to install the seal flush with the cylinder block.

CAUTION: The felt lip must be located inside the flywheel mounting surface. If the lip is not positioned correctly the flywheel could tear the seal.

(4) Install the flywheel or converter drive plate.

New bolts MUST be used when installing the flywheel or converter plate. Tighten the new bolts to 68 N·m (50 ft. lbs.) torque. Turn the bolts an additional 60.

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