Jeep KJ 2005 Service Manual page 1465

9 - 220 2.8L COMMON RAIL DIESEL ENGINE
FLEX PLATE (Continued)
Fig. 92 FLEX PLATE
1 - FLEX PLATE BOLT
2 - FLEX PLATE
(5) Install the flex plate locating pin.
(6) Install the flex plate to the hub and install the
fasteners. Tighten the flex plate fasteners in a cross
sequence to 44 N·m (32.5 ft. lbs.) (Fig. 92).
(7) Install the transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC
INSTALLATION), (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC
INSTALLATION).
CYLINDER LINERS
DESCRIPTION
Each cylinder wall liner used on this engine is of
the wet design. Coolant is in direct contact with the
liner. Three O-rings are used to seal the liner to the
engine block. The top O-rings (black) are water seals
and the lower (brown) seal is an oil seal. The appli-
cable metal shim is used for cylinder liner protru-
sion. If the liner is to be reused, match mark the
liner and block. Anytime that the liners are removed,
replace the O-rings and the shim. If one or more lin-
ers have been replaced the liner protrusion must be
measured to determine the proper head gasket selec-
tion. If the liners are not removed, used the same
thickness head gasket that was removed.
- 42RLE
- 45RFE/545RFE
REMOVAL
CAUTION: To prevent damage to the oil jets,
remove the oil jets before removing the pistons or
liners.
(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-
cial tool VM.1001 to remove liner assembly (Fig. 93).
-
-
Fig. 93 CYLINDER LINER REMOVER
(3) Tighten bolt on VM.1001 to remove liner from
block (Fig. 94).
(4) Remove shim(s) from cylinder liner or cylinder
block recess. Keep shim(s) with each cylinder liner
until cylinder liner protrusion measurement.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
KJ