Jeep Cherokee (XJ): Valve timing. Valve service. Piston fitting

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Engine > 4.0L engine > Service procedures > Valve timing. Valve service. Piston fitting

Valve timing

Disconnect the spark plug wires and remove the spark plugs.

Remove the engine cylinder head cover.

Remove the capscrews, bridge and pivot assembly, and rocker arms from above the No.1 cylinder.

Alternately loosen each capscrew, one turn at a time, to avoid damaging the bridge.

Rotate the crankshaft until the No.6 piston is at top dead center (TDC) on the compression stroke.

Rotate the crankshaft counterclockwise (viewed from the front of the engine) 90.

Install a dial indicator on the end of the No.1 cylinder intake valve push rod. Use rubber tubing to secure the indicator stem on the push rod.

Set the dial indicator pointer at zero.

Rotate the crankshaft clockwise (viewed from the front of the engine) until the dial indicator pointer indicates 0.305 mm (0.012 inch) travel distance (lift).

The timing notch index on the vibration damper should be aligned with the TDC mark on the timing degree scale.

If the timing notch is more than 13 mm (1/2 inch) away from the TDC mark in either direction, the valve timing is incorrect.

If the valve timing is incorrect, the cause may be a broken camshaft pin. It is not necessary to replace the camshaft because of pin failure. A spring pin is available for service replacement.

Valve service

Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and head.

Clean all grime and gasket material from the engine cylinder head machined gasket surface.

Inspect for cracks in the combustion chambers and valve ports.

Inspect for cracks on the exhaust seat.

Inspect for cracks in the gasket surface at each coolant passage.

Inspect valves for burned, cracked or warped heads.

Inspect for scuffed or bent valve stems.

Replace valves displaying any damage.

VALVE REFACING

(1) Use a valve refacing machine to reface the intake and exhaust valves to the specified angle.

(2) After refacing, a margin of at least 0.787 mm (0.031 inch) must remain (Fig. 14). If the margin is less than 0.787 mm (0.031 inch), the valve must be replaced.

Fig. 14 Valve Facing Margin
Fig. 14 Valve Facing Margin

1 - VALVE MARGIN
2 - NO MARGIN

VALVE SEAT REFACING

(1) Install a pilot of the correct size in the valve guide bore. Reface the valve seat to the specified angle with a good dressing stone. Remove only enough metal to provide a smooth finish.

(2) Use tapered stones to obtain the specified seat width when required.

(3) Control valve seat runout to a maximum of 0.0635 mm (0.0025 in.) (Fig. 15).

Fig. 15 Measurement of Valve Seat Runout
Fig. 15 Measurement of Valve Seat Runout

1 - DIAL INDICATOR

VALVE STEM OIL SEAL REPLACEMENT

Valve stem oil seals are installed on each valve stem to prevent rocker arm lubricating oil from entering the combustion chamber through the valve guide bores. One seal is marked INT (intake valve) and the other is marked EXH (exhaust valve).

Replace the oil seals whenever valve service is performed or if the seals have deteriorated.

VALVE GUIDES

The valve guides are an integral part of the engine cylinder head and are not replaceable.

When the valve stem guide clearance is excessive, the valve guide bores must be reamed oversize. Service valves with oversize stems are available in 0.076 mm (0.003 inch) and 0.381 mm (0.015 inch) increments.

Corresponding oversize valve stem seals are also available and must be used with valves having 0.381 mm (0.015 inch) oversize stems.

NOTE: If the valve guides are reamed oversize, the valve seats must be ground to ensure that the valve seat is concentric to the valve guide.

VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT

Valve stem-to-guide clearance may be measured by either of the following two methods.

PREFERRED METHOD

(1) Remove the valve from the head.

(2) Clean the valve stem guide bore with solvent and a bristle brush.

(3) Insert a telescoping gauge into the valve stem guide bore approximately 9.525 mm (.375 inch) from the valve spring side of the head (Fig. 16).

Fig. 16 Measurement of Valve Guide Bore Diameter
Fig. 16 Measurement of Valve Guide Bore Diameter

1 - GAUGE
2 - 9.525 MM (3/8 INCH)
3 - VALVE STEM GUIDE
4 - CYLINDER HEAD

(4) Remove and measure telescoping gauge with a micrometer.

(5) Repeat the measurement with contacts lengthwise to engine cylinder head.

(6) Compare the crosswise to lengthwise measurements to determine out-of-roundness. If the measurements differ by more than 0.0635 mm (0.0025 in.), ream the guide bore to accommodate an oversize valve stem.

(7) Compare the measured valve guide bore diameter with specifications (7.95-7.97 mm or 0.313-0.314 inch). If the measurement differs from specification by more than 0.076 mm (0.003 inch), ream the guide bore to accommodate an oversize valve stem.

ALTERNATIVE METHOD

(1) Use a dial indicator to measure the lateral movement of the valve stem (stem-to-guide clearance).

This must be done with the valve installed in its guide and just off the valve seat (Fig. 17).

(2) Correct clearance is 0.025-0.0762 mm (0.001-0.003 inch). If indicated movement exceeds the specification ream the valve guide to accommodate an oversize valve stem.

NOTE: Valve seats must be ground after reaming the valve guides to ensure that the valve seat is concentric to the valve guide.

Fig. 17 Measurement of Lateral Movement of Valve Stem
Fig. 17 Measurement of Lateral Movement of Valve Stem

1 - DIAL INDICATOR

VALVE SPRING TENSION TEST

Use a universal Valve Spring Tester and a torque wrench to test each valve spring for the specified tension value (Fig. 18).

Replace valve springs that are not within specifications.

Piston fitting

BORE GAGE METHOD

(1) To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.

(2) Measure the inside diameter of the cylinder bore at a point 49.5 mm (1-15/16 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig. 20).

(3) The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The coated piston connecting rod assembly can be used to service previous built engines and MUST be replaced as complete sets. Tin coated pistons should not be used as replacements for coated pistons.

Fig. 18 Valve Spring Tester
Fig. 18 Valve Spring Tester

1 - TORQUE WRENCH
2 - VALVE SPRING TESTER

(4) The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results (Fig. 19). Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.

(5) Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

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