Jeep Cherokee (XJ): Valve springs and oil seals. Cylinder head. Valves and valve springs

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 4.0L engine > Removal and installation > Valve springs and oil seals. Cylinder head. Valves and valve springs

Valve springs and oil seals

This procedure can be done with the engine cylinder head installed on the block.

REMOVAL

Inspect the valve stems, especially the grooves. An Arkansas smooth stone should be used to remove nicks and high spots.

Each valve spring is held in place by a retainer and a set of conical valve locks. The locks can be removed only by compressing the valve spring.

(1) Remove the engine cylinder head cover.

(2) Remove cap screws, bridge and pivot assemblies and rocker arms for access to each valve spring to be removed.

(3) Remove push rods. Retain the push rods, bridges, pivots and rocker arms in the same order and position as removed.

(4) Inspect the springs and retainer for cracks and possible signs of weakening.

(5) Remove the spark plug(s) adjacent to the cylinder( s) below the valve springs to be removed.

(6) Connect an air hose to the adapter and apply air pressure slowly. Maintain at least 621 kPa (90 psi) of air pressure in the cylinder to hold the valves against their seats. For vehicles equipped with an air conditioner, use a flexible air adaptor when servicing the No.1 cylinder.

(7) Tap the retainer or tip with a rawhide hammer to loosen the lock from the retainer. Use Valve Spring Compressor Tool MD-998772A to compress the spring and remove the locks (Fig. 54).

(8) Remove valve spring and retainer (Fig. 54).

(9) Remove valve stem oil seals (Fig. 54). Note the valve seals are different for intake and exhaust valves. The top of each seal is marked either INT (intake/black in color) or EXH (exhaust/brown in color). DO NOT mix the seals.

Fig. 54 Valve and Valve Components
Fig. 54 Valve and Valve Components

1 - VALVE LOCKS (3-BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING

INSTALLATION

CAUTION: Install oil seals carefully to prevent damage from the sharp edges of the valve spring lock grove.

(1) Lightly push the valve seal over the valve stem and valve guide boss. Be sure the seal is completely seated on the valve guide boss.

(2) Install valve spring and retainer.

(3) Compress the valve spring with Valve Spring Compressor Tool MD-998772A and insert the valve locks. Release the spring tension and remove the tool. Tap the spring from side-to-side to ensure that the spring is seated properly on the engine cylinder head.

(4) Release air pressure and disconnect the air hose. Remove the adaptor from the spark plug hole and install the spark plug.

(5) Repeat the procedures for each remaining valve spring to be removed.

(6) Install the push rods. Ensure the bottom end of each rod is centered in the plunger cap seat of the hydraulic valve tappet.

(7) Install the rocker arms, pivots and bridge at their original location.

(8) Tighten the bridge cap screws alternately, one at a time, to avoid damaging the bridge. Tighten the cap screws to 28 N·m (21 ft. lbs.) torque.

(9) Install the engine cylinder head cover.

Cylinder head

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

REMOVAL

(1) Disconnect the battery negative cable.

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

(2) Drain the coolant and disconnect the hoses at the engine thermostat housing and the water pump inlet. DO NOT waste reusable coolant. If the solution is clean and is being drained only to service the engine or cooling system, drain the coolant into a clean container for reuse.

(3) Remove the air cleaner assembly.

(4) Remove the engine cylinder head cover.

(5) Remove the capscrews, bridge and pivot assemblies and rocker arms.

(6) Remove the push rods. Retain the push rods, bridges, pivots and rocker arms in the same order as removed.

(7) Loosen the accessory drive belt at the power steering pump. (Refer to Group 7, Cooling System for the correct procedure). Slip the belt off of the power steering pulley.

(8) Remove the A/C compressor mounting bolts and secure the compressor to the side.

(9) Remove the power steering pump and bracket from the intake manifold and water pump. Set the pump and bracket aside. DO NOT disconnect the hoses.

(10) Perform the Fuel System Pressure Release procedure. (Refer to Group 14, Fuel System) (11) Disconnect the fuel supply line at the fuel rail.

(Refer to Group 14, Quick-Connect Fittings for the correct procedures) (12) Remove the intake and engine exhaust manifolds from the engine cylinder head. (Refer to Group 11, Exhaust System and Intake Manifold for the proper procedures) (13) Disconnect the coil rail electrical connectors and remove the coil rail.

(14) Remove spark plugs.

(15) Disconnect the temperature sending unit wire connector.

(16) Remove the engine cylinder head bolts. Bolt No.14 cannot be removed until the head is moved forward (Fig. 55). Pull bolt No.14 out as far as it will go and then suspend the bolt in this position (tape around the bolt).

(17) Remove the engine cylinder head and gasket (Fig. 55).

(18) If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn't known if they were used before, discard the bolts.

(19) Stuff clean lint free shop towels into the cylinder bores.

NOTE: If the valves, springs, or seals are to be inspected/replaced at this time, refer to Valves and Valve Springs in this section for proper inspection procedures.

INSTALLATION

The engine cylinder head gasket is a composition gasket. The gasket is to be installed DRY. DO NOT use a gasket sealing compound on the gasket.

If the engine cylinder head is to be replaced and the original valves used, measure the valve stem diameter. Only standard size valves can be used with a service replacement engine cylinder head unless the replacement head valve stem guide bores are reamed to accommodate oversize valve stems.

Remove all carbon buildup and reface the valves.

Fig. 55 Engine Cylinder Head Assembly
Fig. 55 Engine Cylinder Head Assembly

1 - CYLINDER HEAD BOLTS
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD

(1) Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil.

(2) Position the engine cylinder head gasket (with the numbers facing up) using the alignment dowels in the cylinder block, to position the gasket.

CAUTION: Engine cylinder head bolts should be reused only once. Replace the head bolts if they were used before or if they have a paint dab on the top of the bolt.

(3) With bolt No.14 held in place (tape around bolt), install the engine cylinder head over the same dowels used to locate the gasket. Remove the tape from bolt No.14.

(4) Coat the threads of stud bolt No.11 with Loctite 592 sealant, or equivalent.

(5) Tighten the engine cylinder head bolts in sequence according to the following procedure (Fig.

56).

CAUTION: During the final tightening sequence, bolt No.11 will be tightened to a lower torque than the rest of the bolts. DO NOT overtighten bolt No.11.

(a) Tighten all bolts in sequence (1 through 14) to 30 N·m (22 ft. lbs.) torque.

(b) Tighten all bolts in sequence (1 through 14) to 61 N·m (45 ft. lbs.) torque.

(c) Check all bolts to verify they are set to 61 N·m (45 ft. lbs.) torque.

(d) Tighten bolts in sequence:

  •  Bolts 1 through 10 to 149 N·m (110 ft. lbs.) torque.
  •  Bolt 11 to 135 N·m (100 ft. lbs.) torque.
  •  Bolts 12 through 14 to 149 N·m (110 ft. lbs.) torque.

CYLINDER HEAD BOLTS

CYLINDER HEAD BOLTS

(e) Check all bolts in sequence to verify the correct torque.

(f) If not already done, clean and mark each bolt with a dab of paint after tightening. Should you encounter bolts which were painted in an earlier service operation, replace them.

Fig. 56 Engine Cylinder Head Bolt Tightening Sequence
Fig. 56 Engine Cylinder Head Bolt Tightening Sequence

(6) Install the spark plugs and tighten to 37 N·m (27 ft. lbs.) torque.

(7) Connect the temperature sending unit wire connector.

(8) Install the ignition coil rail and coil rail electrical connectors.

(9) Install the intake and engine exhaust manifolds (refer to procedures in this section).

(10) Install the fuel line and the vacuum advance hose.

(11) Attach the power steering pump and bracket.

(12) Install the push rods, rocker arms, pivots and bridges in the order they were removed (refer to Rocker Arms and Push Rods in this section).

(13) Install the engine cylinder head cover.

(14) Attach the air conditioner compressor mounting bracket to the engine cylinder head and block.

Tighten the bolts to 40 N·m (30 ft. lbs.) torque.

(15) Attach the air conditioning compressor to the bracket. Tighten the bolts to 27 N·m (20 ft. lbs.) torque.

CAUTION: The serpentine drive belt must be routed correctly. Incorrect routing can cause the water pump to turn in the opposite direction causing the engine to overheat.

(16) Install the serpentine drive belt. (refer to Group 7, Cooling System for the proper procedure).

(17) Install the air cleaner and ducting.

(18) Connect the hoses to the engine thermostat housing and fill the cooling system to the specified level (refer to Group 7, Cooling Systems for the proper procedure).

(19) The automatic transmission throttle linkage and cable must be adjusted after completing the engine cylinder head installation (refer to Group 21, Transmissions for the proper procedures).

(20) Install the temperature sending unit and connect the wire connector.

(21) If equipped with air conditioning, install A/C compressor and charge A/C system (refer to Group 24 Heating and Air Conditioning).

(22) Connect negative cable to battery.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH THE FAN. DO NOT PUT HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

(23) Operate the engine with the radiator cap off.

Inspect for leaks and continue operating the engine until the engine thermostat opens. Add coolant, if required.

Valves and valve springs

This procedure is done with the engine cylinder head removed from the block.

REMOVAL

(1) Remove the engine cylinder head from the cylinder block.

(2) Use Valve Spring Compressor Tool MD-998772A and compress each valve spring.

(3) Remove the valve locks, retainers, springs and valve stem oil seals. Discard the oil seals.

(4) Use a smooth stone or a jewelers file to remove any burrs on the top of the valve stem, especially around the groove for the locks.

(5) Remove the valves, and place them in a rack in the same order as removed.

INSTALLATION

(1) Thoroughly clean the valve stems and the valve guide bores.

(2) Lightly lubricate the stem.

(3) Install the valve in the original valve guide bore.

(4) Install the replacement valve stem oil seals on the valve stems. If the 0.381 mm (0.015 inch) oversize valve stems are used, oversize oil seals are required.

(5) Position the valve spring and retainer on the engine cylinder head and compress the valve spring with Valve Spring Compressor Tool MD-998772A.

(6) Install the valve locks and release the tool.

(7) Tap the valve spring from side to side with a hammer to ensure that the spring is properly seated at the engine cylinder head. Also tap the top of the retainer to seat the valve locks.

(8) Install the engine cylinder head.

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