Cylinder Head Cover(S) Removal; Installation; Valve Springs; Removal - Jeep 2002 WJ Service Manual

WG
CYLINDER HEAD (Continued)
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
(8) Start engine and inspect for leaks.
CYLINDER HEAD COVER(S)

REMOVAL

(1) Disconnect negative battery cable.
(2) Detach hose from oil separator.
(3) Disconnect fuel injector and glow plug harness
and set aside.
(4) Remove fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(5) Remove cylinder head cover retaining bolts and
remove cover.

INSTALLATION

(1) Position cylinder head cover with new gasket
and install bolts. Tighten bolts to 20 N·m (177 lbs.
in.).
(2) Install and properly route fuel injector and
glow plug wiring harness, making appropriate con-
nections.
(3) Install injectors and high pressure pipes (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - INSTALLATION).
(4) Attach oil seperator hose.
(5) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(6) Start engine and inspect for leaks.

VALVE SPRINGS

REMOVAL

REMOVAL - VALVE SPRINGS

(1) Disconnect negative battery cable.
(2) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(3) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL
REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
COVER(S) - REMOVAL).
(5) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
AND SPROCKETS - REMOVAL).
(6) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(7) Remove top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(8) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: The timing chain must be held in up position
so as not to jam during procedure.
(9) Position piston of cylinder to be processed to
DTC by rotating the crankshaft clockwise.DO NOT
crank engine.DO NOT rotate engine backward.
(10) Install crankshaft lock, special tool #8932.
(11) Seal injector hole with connection piece and
retain with orginal tensioning claw.
(12) Connect cylinder leak tester with adaptors
and pressurize the cylinder to 5 bar (73 psi.).
WARNING: Valve springs and retainers must be
kept in order of the cylinder they were removed.
NOTE:
threaded edge of cylinder head and position thrust
piece vertically at top of valve spring retainer.
(13) Compress valve spring.
(14) Remove valve keepers.
(15) Remove top valve spring retainer and valve
spring.
(16) Remove valve stem seals.
(17) Remove bottom valve spring retainer.
NOTE: Inspect all cylinder head components for
wear or damage.
(18) Repeat procedure for each cylinder as neces-
sary.

REMOVAL - VALVES

(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Place insertion plate into the assembly board
in direction of arrows on assembly board.
(3) Mount cylinder head onto assembly board with
its front side pointing in direction of arrow on assem-
bly board.
(4) Attach valve assembly tool to cylinder head.
INJECTOR -
HEAD/CYLINDER
TIMING/TIMING
Using tool, screw
ENGINE 9a - 21
HEAD
BELT/CHAIN
retaining fork into