ENGINE WJ 9-1 ENGINE CONTENTS page page GENERAL INFORMATION ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . 1 HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING SERVICE DIAGNOSIS—DIESEL— MECHANICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SERVICE DIAGNOSIS—DIESEL— PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3 TAPPET NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SERVICE PROCEDURES VALVE SERVICE . . . . . . . . .
9-2 ENGINE WJ GENERAL INFORMATION (Continued) Engine Description Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these 2 conditions could be responsible for noisy tappets: OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil.
WJ DIAGNOSIS AND TESTING SERVICE DIAGNOSIS—DIESEL—PERFORMANCE ENGINE 9-3
9-4 ENGINE DIAGNOSIS AND TESTING (Continued) WJ
WJ DIAGNOSIS AND TESTING (Continued) ENGINE 9-5
9-6 ENGINE DIAGNOSIS AND TESTING (Continued) WJ
WJ DIAGNOSIS AND TESTING (Continued) ENGINE 9-7
9-8 ENGINE DIAGNOSIS AND TESTING (Continued) WJ
WJ DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—DIESEL—MECHANICAL.
9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) WJ
WJ DIAGNOSIS AND TESTING (Continued) ENGINE 9 - 11
9 - 12 ENGINE WJ DIAGNOSIS AND TESTING (Continued) TAPPET NOISE VALVE CLEANING (1) To determine source of tappet noise, operate engine at idle with cylinder head covers removed. (2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. (1) Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and head.
ENGINE WJ 9 - 13 SERVICE PROCEDURES (Continued) VALVE STAND DOWN Valve stand down is to maintain the adequate compression ratio. (1) Invert cylinder head. (2) Fit each valve to its respective valve guide. (3) Using a straight edge and feeler gauge (Fig. 4), check valve head stand down: Inlet valve head stand down .80 to 1.2 mm (.031 to .047 in.) and exhaust valve stand down .79 to 1.19 mm (.031 to .047 in).
9 - 14 ENGINE WJ SERVICE PROCEDURES (Continued) (3) Subtract diameter of valve stem from internal diameter of its respective valve guide to obtain valve stem clearance in valve guide. Clearance of inlet valve stem in valve guide is .040 to .075 mm (.0015 to .0029 in). Clearance of exhaust valve stem in valve guide is .060 to .095 mm (.0023 to .0037 in). (4) If valve stem clearance in valve guide exceeds tolerances, new valve guides must be installed.
ENGINE WJ 9 - 15 REMOVAL AND INSTALLATION (Continued) (22) Remove the hood latch support brackets from the vehicle. (23) Remove the upper fan shroud retaining bolts. (24) Remove the radiator crossmember from the vehicle. (25) Remove the manual cooling fan and let set inside of the fan shroud. (27) Disconnect the breather hose and remove the fresh air inlet tube from the vehicle (Fig. 9). (28) Remove the radiator overflow hose from the radiator (29) Remove the upper radiator hose from the vehicle.
9 - 16 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 11 Engine Compartment View - Rightside Fig. 12 Power Steering Fluid Lines At Pump (40) Remove the heater core coolant supply lines from the engine assembly (Fig. 11). (41) Remove the refrigerant line from the A/C accumulator assembly. (42) Disconnect the oil pressure and boost pressure sensor electrical connectors and unclip wire harness from the coolant supply lines. (43) Disconnect the engine ground. Located just behind the oil filter.
ENGINE WJ 9 - 17 REMOVAL AND INSTALLATION (Continued) NOTE: Mark the position of the torque convertor in relation to the driveplate through the starter motor access hole. This reference mark will be used to line up the two components for reassemble. Fig. 14 Transmission Dipstick Tube Support Bracket (58) Remove the transmission dipstick tube support bracket retaining nut from the turbocharger heatshield (Fig. 14). (59) Raise the vehicle on the hoist. (60) Disconnect the starter motor electrical. Fig.
9 - 18 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 19 Engine Mount Sill Plate Retaining Bolts Right Wheel Well Fig. 17 Transmission Support Crossmember Fig. 18 Engine Mount Sill Plate Retaining Bolts Left Wheel Well (76) Remove the left engine mount sill plate retaining bolts (Fig. 20). (77) Remove the right engine mount sill plate retaining bolts (Fig. 21). (78) Set up an engine lifting device and support the weight of the engine assembly.
WJ ENGINE 9 - 19 REMOVAL AND INSTALLATION (Continued) (4) Working between the bulkhead and the right rear of the engine assembly, connect the engine misfire sensor electrical connector. (5) Using the engine lifting device and/or the jack under the transmission, position the engine/transmission assembly so the engine block mounted dowel pins are perfectly aligned with the corresponding holes in the transmission bellhousing.
9 - 20 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 25 Engine Mount Sill Plate Bolts - Left Wheel Well Fig. 23 Engine Mount Sill Plate Bolts - Rightside (21) Lower the transmission and transfer case assembly enough to gain access to the upper six bellhousing bolts. NOTE: Be certain all brackets that were originally installed on the bellhousing bolts are reinstalled. Cable misrouting could result. (22) Install the upper six bellhousing bolts. Torque the bolts to 102 N·m (75 ft. lbs.). Fig.
ENGINE WJ 9 - 21 REMOVAL AND INSTALLATION (Continued) (23) Raise the transmission assembly back into position and install the eight transmission crossmember retaining bolts (Fig. 26). Torque the bolts to 41 N·m (30 ft. lbs.). NOTE: Be certain the torque convertor is properly aligned with the driveplate before attempting to installing the retaining bolts.
9 - 22 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (31) Install the wire harness mounting bracket and retaining nuts on the left engine mount. Torque the nuts to 25 N·m (221 in. lbs.). (32) Connect the fuel supply and return hoses on the engine assembly. (33) Connect the speed control servo vacuum supply hose on the engine mounted steel vacuum source line. (34) Install the battery feed wire on the top of the generator and install the cover.
ENGINE WJ 9 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 32 Cooling Module Assembly Fig. 34 Intercooler Hoses (55) Connect the electric radiator cooling fan electrical connector. (56) Install the intake air duct on the vehicle (Fig. 32). (57) Install the upper radiator hose on the vehicle. (58) Install the radiator overflow hose on the radiator (60) Install the intercooler inlet and outlet hoses on the engine (Fig. 34). (61) Install the manual cooling fan on the engine.
9 - 24 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (1) Disconnect the negative battery cable. (2) Raise the vehicle on a hoist. WARNING: DO NOT LOOSEN THE RADIATOR VENT OR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR (3) Drain the cooling system. Refer to Group 7, Cooling System for procedure. Fig. 35 Transmission Fluid Cooler Lines (75) Install the lower radiator hose on the radiator (Fig. 35).
ENGINE WJ 9 - 25 REMOVAL AND INSTALLATION (Continued) Fig. 37 Air Intake Hoses Fig. 39 Transmission Dipstick Tube Support Bracket WARNING: Heatshield is very sharp. Wear gloves to prevent injury. (19) Remove the exhaust manifold / turbocharger heatshield retaining bolts and remove the heatshield from the vehicle. (20) Pull back the EGR tube heatshield to access and remove the EGR tube nut from the exhaust manifold. Remove the EGR valve and tube assembly from the vehicle.
9 - 26 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 40 Intake Manifold Retaining Nuts Fig. 41 Turbocharger Retaining Nuts (29) Remove the (10) intake manifold retaining bolts and remove the intake manifold from the vehicle (Fig. 40). (30) Remove the intake/exhaust manifold gasket from the manifolds mounting studs. (7) Install the exhaust manifold retaining nuts and torque to 32 N·m (23 ft. lbs.). (8) Install the transmission dipstick tube in the transmission case. (9) Remove the drain pan.
ENGINE WJ 9 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 42 Transmission Dipstick Tube Support Bracket Fig. 44 Air Intake Hoses (22) Install the intercooler inlet hose on the vehicle (Fig. 44). (23) Raise the vehicle on the hoist. (24) Install the turbocharger oil return hose on the turbocharger. Fig. 43 3.1L Diesel Engine (18) Install the heater core coolant supply hoses on the coolant line assembly (Fig. 43). (19) Clip the wire harness on the coolant supply lines (Fig. 43).
9 - 28 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (27) Fill the cooling system. Refer to Group 7, Cooling System for procedure. (28) Check the transmission fluid level and top off if necessary. (29) Connect the negative battery cable. (30) Start the engine and check for leaks. CYLINDER HEAD COVER REMOVAL (1) Disconnect the negative battery cable. (2) Recover the refrigerant system. Refer to Group 24, Heating and Air Conditioning for the procedure. (3) Raise the vehicle on the hoist.
ENGINE WJ 9 - 29 REMOVAL AND INSTALLATION (Continued) (10) Install the left engine mount throughbolt nut. Torque the nut to 61 N·m (45 ft. lbs.). (11) Install the low pressure refrigerant line and retaining bolt. Torque the bolt to 28 N·m (21 ft. lbs.). Be certain the sealing o-ring is well lubricated and free of tears. (12) Install the front splash shield. (13) Lower the vehicle on the hoist. (14) Connect the negative battery cable. (15) Evacuate and charge the refrigerant system.
9 - 30 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (5) Remove cylinder head cover. Refer to cylinder head cover removal and installation procedure in this section. (6) Remove the rocker assemblies and push rods. Refer to rocker arms and push rod removal and installation procedure in this section. Identify push rods to ensure installation in original location. (7) Remove cylinder head, intake manifold, and exhaust manifold. Refer to cylinder head removal and installation in this section.
ENGINE WJ 9 - 31 REMOVAL AND INSTALLATION (Continued) • At this point tighten the rocker arm nuts for cylinder # 2–3–4–5. Torque nuts to 27 N·m (20 ft. lbs.). • Slowly rotate the crankshaft 90° clockwise or counterclockwise, then tighten the rocker arm nuts for cylinder # 1. Torque nuts to 27 N·m (20 ft. lbs.). (4) Install the cylinder head cover. Refer to cylinder head cover removal and installation in this group. (5) Evacuate and charge the air conditioning system.
9 - 32 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (4) Repeat the procedures for each remaining valve spring to be removed. (5) Install the push rods. Ensure the bottom end of each rod is centered in the plunger cap seat of the hydraulic valve tappet. WARNING: During the installation of the rocker arm assemblies it is possible to cause valve interference between the piston and valve if the piston is near Top Dead Center (TDC).
ENGINE WJ 9 - 33 REMOVAL AND INSTALLATION (Continued) (15) Disconnect the oil feed line from turbocharger. (16) Disconnect the oil return line from turbocharger (Fig. 58). Fig. 56 Heater Hoses (14) Remove the exhaust manifold/turbocharger heat shield (Fig. 57). Fig. 58 Oil Return Line (17) Raise vehicle on hoist. (18) Disconnect the exhaust pipe at the turbocharger. (19) Remove the Exhaust manifold and turbocharger. Refer to Group 11, Exhaust System and Turbocharger.
9 - 34 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 61 Fuel Injector Tool VM.1012 Fig. 59 Cylinder Head Oil Supply Line Retaining Clip Fig. 62 Fuel Injector (31) Remove the push rods and place them on a bench in the same order as removed. (32) Mark the cylinder head positions. (33) Remove the engine cylinder head bolts with special tool VM.1018 and VM.1019. (34) Remove the engine cylinder head and gasket . (35) Stuff clean lint free shop towels into the cylinder bores.
ENGINE WJ 9 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 63 Rocker Arm Retaining Nuts Fig. 65 Steel Type Cylinder Head Gasket— identification CAUTION: Piston protrusion must be measured, to determine cylinder head gasket thickness, if one or more cylinder wall liners have been replaced. NOTE: If cylinder wall liners have not been removed; the same thickness head gasket removed, may be used. Fig. 64 Rocker Arm Assemblies MEASURING PISTON PROTRUSION (1) Use special tool VM.
9 - 36 ENGINE WJ REMOVAL AND INSTALLATION (Continued) on the block and secure with the twelve large center bolts and spacers (clamps), finger tight only. b. Ensure that the various clamps are installed correctly and the head gasket remains in it’s proper position, completely covered. Then, lubricate and install the ten small bolts, also finger tight. (6) Install the intake and exhaust manifolds with a new gasket, partially tightening the nuts to a maximum of 5 N·m (44 in. lbs.).
ENGINE WJ 9 - 37 REMOVAL AND INSTALLATION (Continued) (10) Side bolts (M1-M2): Tighten M1 bolts to 30 N·m, then rotate them 85° (65). Tighten M2 bolts to 30 N·m, then rotate them 85° (65). 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 operation at operating temperature, allow engine to cool down completely.
9 - 38 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 72 Cylinder Head Cover Fig. 71 Rocker Arm Assemblies (27) Lower vehicle form hoist. (28) Install the exhaust manifold/turbocharger heat shield. Torque bolts to 11 N·m (8 ft. lbs.). (29) Install the heater core supply lines. (30) Install the EGR valve/heater core supply line retaining bolts. Torque bolts to 28 N·m (20 ft. lbs.). (31) Install the intercooler hose to turbocharger. (32) Install the air cleaner hose to turbocharger.
ENGINE WJ 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 74 Timing Gear Cover Oil Seal Fig. 73 VM.1000–A INSTALLATION (1) Install the vibration damper and align with key way. (2) Install the vibration damper nut. Torque nut to 196 N·m (147 ft. lbs.). (3) Install the accessary drive belt. Refer to Group 7, Cooling System for procedure. (4) Connect the negateive battery cable. TIMING GEAR COVER OIL SEAL REMOVAL (1) Disconnect the negative battery cable. (2) Remove the vibration damper.
9 - 40 ENGINE WJ REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Be sure the mating surfaces of the gear case cover and the cylinder block are clean and free from burrs. (2) Apply a continuous 3 mm bead of Silicone Sealer (Fig. 78) to timing cover, install within 10 minutes, tighten 6mm bolts to 11 N·m (8 ft. lbs.) and tighten 8mm bolts to 26.2 N·m (19 ft. lbs.). (3) Install Power steering pump pulley. Torque bolts to 25 N·m (18 ft. lbs.). (4) Install the automatic belt tensioner.
ENGINE WJ 9 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 79 Timing Marks Fig. 78 Front Cover Sealer Location CAMSHAFT REMOVAL (1) Disconnect the negative battery cable. (2) Remove the cylinder head cover. Refer to cylinder head cover removal and installation in this section. (3) Remove the cylinder heads. Refer to cylinder head removal and installation in this section. (4) Remove the rocker arm assemblies, push rods, and hydraulic tappets. Refer to the respective groups in this section.
9 - 42 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (5) Install the cylinder head cover. Refer to cylinder head cover removal and installation in this section. (6) Install the timing gear cover. Refer to timing gear cover removal and installation in this section. (7) Install the vibration damper. Refer to the vibration damper removal and installation in this section. (8) Install the radiator, A/C condensor, and intercooler. Refer to Group 7, Cooling System for procedure.
ENGINE WJ 9 - 43 REMOVAL AND INSTALLATION (Continued) (2) Remove the timing gear cover. Refer to timing gear cover removal and installation in this section. (3) Remove the oil pump (Fig. 84). Fig. 83 VM.1040 OIL PAN Fig. 84 Oil Pump Removal REMOVAL (1) (2) (3) (4) (5) bolts (6) Disconnect the negative battery cable. Raise the vehicle on hoist. Drain the oil. Remove the oil pan lower cover. Remove the bolts from oil pan. Remove the 6 that are on the inside of the oil pan. Remove the oil pan.
9 - 44 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 85 Timing Marks Fig. 86 Vacuum Pump OIL PUMP PRESSURE RELIEF VALVE REMOVAL (1) Disconnect the negative battery cable (2) Remove the oil pan. Refer to oil pan removal and installation procedure in this section. (3) Remove the relief valve snap ring. (4) Remove the relief valve cap, spring, and plunger (Fig. 89). Fig. 87 Vacuum Pump Parts Fig. 88 Vacuum Pump Mounting Hole (5) Check the relief valve spring length.
ENGINE WJ 9 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 89 Oil Pressure Relief Valve Fig. 90 Oil Filter Housing (2) Fit plunger, spring and cap into block. (3) Compress spring and install the snap ring. Ensure the snap ring is completely seated in groove. (4) Install the oil pan. Refer to oil pan removal and installation procedure in this section. (5) Connect the negative battery cable. OIL FILTER ADAPTER AND OIL COOLER REMOVAL (1) Disconnect the negative battery cable.
9 - 46 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 94 Oil Filter Housing Cap Fig. 92 Oil Filter Position & Orientation (2) Install the new filter element in the housing and install cap. Torque to 22.5 N·m (194in. lbs.) (Fig. 94). (3) Install the oil filter housing drain plug. Torque to 12 N·m (106in. lbs.). (4) Lower the vehicle on hoist. (5) Fill the engine oil level to specification. (6) Start the engine and check for leaks.
ENGINE WJ 9 - 47 REMOVAL AND INSTALLATION (Continued) (2) Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 96). (3) Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. (4) Carefully clean carbon from piston crowns, skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are clear. PISTON RING FITTING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
9 - 48 ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 100 Piston Ring Identification PISTON PIN INSTALLATION (1) Secure connecting rod in soft jawed vice. (2) Lubricate piston pin and piston with clean oil. (3) Position piston on connecting rod. Fig. 98 Piston Ring to Groove Clearance CAUTION: Ensure combustion recess in piston crown and the bearing cap numbers on the connecting rod are on the same side. (4) Install piston pin. (5) Install clips in piston to retain piston pin.
ENGINE WJ REMOVAL AND INSTALLATION (Continued) Fig. 101 Piston Ring Gap Location Fig. 103 Liner Removal Tool Fig. 102 Installing Piston rod and piston into cylinder bore and guide rod over the crankshaft journal. (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (7) Install rod caps. Install cleaned and oiled rod bolts. Torque bolts to 29.5 N·m (22 ft. lb.) plus 60°.
9 - 50 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (4) Remove shims from cylinder liner or cylinder block recess. Keep shims with each cylinder liner. Fig. 105 Liner Inspection INSTALLATION (1) Carefully clean residual LOCTITE from liner and crankcase, and degrease the crankcase where it comes into contact with the liners. Install the liners in the crankcase as shown (A), rotating them back and forth by 45° in order to guarantee correct positioning (Fig. 106).
ENGINE WJ 9 - 51 REMOVAL AND INSTALLATION (Continued) (8) Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat. Lock the liners in position using special tool (VM-1016) and bolts (Fig. 107). Clean the residual LOCTITE on the upper surface of the block deck. (8) Remove the water manifold. (9) Remove the oil feed lines to rocker arms. (10) Remove the cylinder heads. Refer to cylinder head removal and installation in this section.
9 - 52 ENGINE WJ REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Be sure that the oil hole in the main bearing lines up with the oil gallery hole in the cylinder block. (1) Using the VM.1002 push the front main bearing into the cylinder block (Fig. 111). Fig. 109 Crankshaft and Carrier Bearing Assembly Fig. 111 Crankshaft Front Main Bearing Installation (2) Fit the main bearing supports together. Torque to 44 N·m (32 ft. lbs.) (3) Check internal diameter of bearings.
ENGINE WJ 9 - 53 REMOVAL AND INSTALLATION (Continued) (8) Slide special tool VM.1004 over the crankshaft gear and, insert the crankshaft and support assembly into the crankcase in the same manner used for removal. (9) Align the holes in the lower supports, with the center of the crankcase webs (Fig. 112). (21) Subtract specified crankshaft end play from figure obtained. Crankshaft end play 0.08 to 0.28 mm (.0060 to .0119 in.). (22) Select thrust washers which will give correct end play.
9 - 54 ENGINE WJ REMOVAL AND INSTALLATION (Continued) (31) Install the oil pan. Refer to oil pan removal and installation in this section. (32) Install the vacuum pump, being careful to align the gear timing marks with those on the crankshaft gear. Torque screws to 20 N·m (15 ft. lbs.). (33) Before installing the oil pump check pump bore depth in block (A) and pump body height (B) (Fig. 114). Difference between A and B should be 0.020-0.082 mm (.0007 to 0032 in.).
ENGINE WJ 9 - 55 CLEANING AND INSPECTION (Continued) INSPECTION Fig. 115 Checking Cylinder Head Flatness ROCKER ARMS AND PUSH RODS CLEANING Clean all the components (Fig. 116) with cleaning solvent. Inspect the pivot surface area of each rocker arm. Replace any that are scuffed, pitted, cracked or excessively worn. Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted. Inspect each push rod end for excessive wear and replace as required.
9 - 56 ENGINE WJ CLEANING AND INSPECTION (Continued) NOTE: On one side of the big end of the con-rod there is a two-digit number which refers to the weight category. On the other side of the big end there is a four digit number on both the rod and the cap. These numbers must both face the camshaft as well as the recess on the piston crown (Fig. 118). Lightly heat the piston in oven. Insert piston pin in position and secure it with provided snap rings.
ENGINE WJ 9 - 57 CLEANING AND INSPECTION (Continued) Fig. 120 Liner Inspection OIL PUMP Fig. 122 Oil Pump Inner and Outer Rotors (2) Check clearance between rotors (Fig. 123). CLEANING Wash all parts in a suitable solvent and inspect carefully for damage or wear. INSPECTION (1) Before installing oil pump check pump bore depth in block (A) and pump body height (B) (Fig. 121). Difference between A and B should be 0.020-0.082 mm. Fig. 123 Checking Rotor Clearance Fig.
9 - 58 ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS WJ
WJ SPECIFICATIONS (Continued) ENGINE 9 - 59
9 - 60 ENGINE WJ SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Adaptor Plate to Block Nuts (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m Automatic Belt Tensioner to Block Bolts (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 N·m Automatic Belt Tensioner to Mounting Bracket Bolt (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m Generator belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE WJ 9 - 61 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N·m Turbocharger Mounting nuts . . . . . . . . . . . . . . . . . . . . . . 32.5 N·m Turbocharger Oil delivery fitting . . . . . . . . . . . . . . . . . . . 27.5 N·m Turbocharger oil drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 N·m Vacuum pump Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m Water manifold Bolts . . . .
9 - 62 ENGINE WJ SPECIAL TOOLS (Continued) Torque Angle Gauge VM. 1005 Cylinder Liner Protrusion Tool VM. 1010 Cylinder Head Bolt Wrench VM. 1006A Bosch Pump Timing Adapter VM. 1011 Cylinder Head Guide Studs VM. 1009 Injector Remover/Installer Socket VM.
ENGINE WJ 9 - 63 SPECIAL TOOLS (Continued) Dial Indicator Gauge VM. 1013 Cylinder Retainer VM. 1016 Flywheel Locking Tool VM. 1014 Crankshaft and Water Pump Pulley Holder VM. 1017 Timing Cover Oil Seal Installer VM.
9 - 64 ENGINE WJ SPECIAL TOOLS (Continued) Cylinder Head Bolt Wrench M12 VM. 1018 Cylinder Leakage Tester Adapter VM. 1021 Cylinder Head Bolt Wrench M14 VM. 1019 Fig. 124 Camshaft Bearing Remover/Installer VM.
