Jeep Cherokee (XJ): Repair damaged or worn threads. Service engine assembly (short block). Hydrostatic lock

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 2.5L engine > Service procedures > Repair damaged or worn threads. Service engine assembly (short block). Hydrostatic lock

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.

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 of the cylinder block, crankshaft, piston and rod assemblies. If needed, the camshaft must be procured separately and installed before the engine is installed in the vehicle.

A short block is identified with the letter "S" stamped on the same machined surface where the build date code is stamped for complete engine assemblies.

Installation includes the transfer of components from the defective or damaged original engine. Follow the appropriate procedures for cleaning, inspection and torque tightening.

Hydrostatic lock

When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.

(1) Perform the Fuel Pressure Release Procedure (refer to Group 14, Fuel System).

(2) Disconnect the negative cable from the battery.

(3) Inspect air cleaner, induction system and intake manifold to ensure system is dry and clear of foreign material.

(4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the plugs from the engine.

CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.

(5) With all spark plugs removed, rotate the crankshaft using a breaker bar and socket.

(6) Identify the fluid in the cylinders (i.e. coolant, fuel, oil, etc.).

(7) Make sure all fluid has been removed from the cylinders.

(8) Repair engine or components as necessary to prevent this problem from occurring again.

(9) Squirt engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.

(10) Install new spark plugs. Tighten the spark plugs to 37 N·m (27 ft. lbs.) torque.

(11) Drain engine oil. Remove and discard the oil filter.

(12) Install the drain plug. Tighten the plug to 34 N·m (25 ft. lbs.) torque.

(13) Install a new oil filter.

(14) Fill engine crankcase with the specified amount and grade of oil (refer to Group 0, Lubrication and Maintenance).

(15) Connect the negative cable to the battery.

(16) Start the engine and check for any leaks.

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