Jeep 200 Cherokee, Service Manual

Page: 1278 / 2119

(9) Tighten the 12mm bolts in the following man-
ner:
(10) Side bolts (M1-M2): Tighten M1 bolts to 30
N·m, then rotate them 85° (
6
5). Tighten M2 bolts to
30 N·m, then rotate them 85° (
6
5).
NOTE: If vehicle is equipped with A/C do not install
A/C lines to compressor and charge A/C till Phase 2
is complete.
(11) 2nd Phase: After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(12) Central bolts A-L: Completely back off bolts
one-by-one and then retighten to 30 N·m plus 130°
(
6
5°). Then proceed in the same way, bolt by bolt,
following alphabetical order, as indicated.
(13) Side bolts M1-M2: Without slackening,
torque bolts M1 then bolts M2 to 90 N·m (66 ft. lbs.).
(14) Torque intake nuts to 32 N·m (24 ft. lbs.) and
exhaust manifolds nuts to 32 N·m (24 ft. lbs.) after
completing the cylinder head torquing procedure.
(15) Install the oil feed lines for the rocker arm
assemblies. Torque oil feed lines to 13 N·m (115 in.
lbs.).
(16) Install the oil feed line retaining bracket at
rear of #4 cylinder head (Fig. 29).
(17) Install the push rods and rocker arm assem-
blies. Refer to the rocker arm and pushrod removal
and installation procedure in this group.
(18) Install the cylinder head cover. Torque bolts to
15 N·m (133 in. lbs.).
(19) Connect the crankcase breather hose.
(20) Connect the injector sensor wire and the glow
plug hot lead.
(21) Install the turbocharger oil feed line. Torque
banjo bolts to 27 N·m (20 ft. lbs).
(22) Install the turbocharger oil drain line. Torque
bolts to 11 N·m (97 in. lbs.).
(23) Install the water manifold. Torque bolts to 12
N·m (106 in. lbs.).
(24) Install the generator support bracket.
(25) Raise the vehicle on hoist.
(26) Install the exhaust down pipe to turbocharger,
tighten bolts to 22 N·m (16 ft. lbs.).
(27) Install the exhaust down pipe heat shield.
(28) Install the exhaust heat shield, Tighten bolts
to 11 N·m (8 ft. lbs.).
(29) Install the EGR valve to intake manifold,
tighten bolts to 27 N·m (20 ft. lbs.).
(30) Install the EGR tube to EGR valve, tighten
bolts to 27 N·m (20 ft. lbs.).
(31) Install the lower charge air cooler hose to tur-
bocharger.
(32) Install the air cleaner assembly and hose.
(33) Install the oil breather hose to air cleaner
hose.
(34) Install the upper charge cooler hose to turbo-
charger.
(35) Connect the recover bottle hose to water man-
ifold.
(36) Install the fuel injectors using special tool
VM.1012. Refer to Group 14, Fuel System for proce-
dures.
(37) Install the fuel injector lines from the pump
to injectors. Torque nuts to 19 N·m (14 ft. lbs.).
(38) Connect the A/C lines to compressor and
install bracket on cylinder head cover, if equipped
with air conditioning.
(39) Install the fuel filter, Tighten bolts to 28 N·m
(250 in. lbs.)
(40) Connect the fuel supply and return lines
(41) Connect the upper radiator hose.
(42) Connect the negative cable battery.
(43) If equipped with A/C, evacuate and charge the
air conditioning system. Refer to Group 24, Heater
and Air Conditioning.
(44) Fill the cooling system. Check for leaks.
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.
(45) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
NOTE: After rebuild or cylinder head gasket
replacement, the cylinder head must be retorqued
within the first 20,000km. If individual fiber type
head gaskets were used.
NOTE: The one piece steel type head gasket does
not require, the above mentioned, retorque proce-
dure.
CYLINDER HEAD RE-TORQUE
Within the first 20,000 km (12,000 miles) after
rebuild, retorque the cylinder head bolts as follows:
(Fig. 37) Central bolts A-L: Without slackening the
bolts, following alphabetical order tighten the bolts
through an angle of 15°. Side bolts M1-M2: Without
slackening, tighten M1 then M2 bolts through an
angle of 15°.
XJ
ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)