90 Cherokee XJ rebuilding
 

I started with doors but turned into something bigger that I didn't plan at all :)
have couple of holes in trunk and bottom. nothing with chassis yet.

dissembling it into pieces time consuming and still on going, some nuts/bolts are quite rusty.

all suggestions are welcome.

removed the carpet and usual ones

removed interior parts all of them. including console but still in that pic :P

quick check on injectors. 3 out of 6 were fine. cleaned them up with ultrasonic cleaner.
got better ohm values after cleaning. from 14.8 to 16.5 ohms something.

here comes the cylinder head off.

rocker arms and cam shifters before cleaning and after 2 rounds of 15 min with ultrasonic cleaner. now left them de greaser for night to get all dirt out.

pics here.

needed something to keep the engine hanging and adjust... wanted to do it before putting it back.

was fighting with this bolt on top gearbox for 2 hrs to get it out. had to lower transfer case and engine.

Is this going to be a total rebuild, to atoms and back together? Looking like so... And looking good too.

Do you have pdf links for engine diagrams?

Maybe you should open hydraulic lifters to get dirt out from them. There is small snapring in top of lifter, after that piston and valve will come out and you can clean lifter from inside and check inner bore condition also. Dont mix pistons and valves to other lifters, and becarefull snaprings will fly cross the room when you twist it avay with skrewdriver!

thanks, I guess I will open them too. those passages didn't seem so clean at all. I don't have every right tool so I need to figure out something to open them.

Yes It is going to be a full rebuild. Probably will be the slowest one ever, coz I am doing everything myself.
I have only the part catalogs from morris jeep downloaded. checking them when needed.

http://www.jeep4x4center.com/knowledge-base/index.htm

You need just 2 skrewdriver. With bigger one you press piston down 1mm and with smaler one you take snapring out. Little magnet will help you to take piston and valve out from lifter.

After you have assembled lifters back together sink them to motor oil and pump few times piston to fill it with oil. You can feel when piston wont compress anymore, then its full.

finally took out engine, transmission and transfer case. couldn't take them out one piece since I don't have anything that high to hang roller.

engine needs a lot of new parts and seals that I know well. been spitting out a lot of oil from every single place. before removing was hardly making 80km/h and puking oil into air-filter. long list of problems.

transmission is still in good condition I will replace only its oil filter and do some cleaning outside to make it breath more.

transfer case had some switching problems not always. I will replace shift fork pads for now. chain seems ok. not so bad.

sure, thanks for the tip, will do that. for now they have wait since I can do that as very last step before closing the valve cover :)

finally got the shift fork rail out. have been fighting to take out that pin (in picture). took it somewhere too but the guy there didn't have any idea and said it has nothing to do with that pin. so came back home, checked the diagrams for np242, the pin was the only way to get the forks out and kept fighting till I find the right screw.

there is slight damage on side where the front output fork sits on the rail. can it be my shifting problem? it was getting stuck when switching from 4x2 to 4x4 high/low.

managed to clean up the cover. it wasn't that easy though. did a bit sanding inside and outside to get smoother surface and painted.

time to have hot bath :) washed the engine block and transmission with pressured hot water. pressure wasn't enough ( Karcher K4.99 ) but still did a good job, something with 160 - 180 bar would do a lot better though. that W5 cleaner made it a lot easier. yes I did lubricate after washing it with water. don't want them get rusty.

oil passages around lifters got cleaner that I could notice them. and did a bit honing on piston skirts since there will be new rings coming.

yet couldn't remove the pulley, I don't wanna heat it up to pull out, waiting for pulley removing tool. probably will get it soon.

removed the pulley and got the everything out from the block. meanwhile ordered a new timing chain.

did one more cleaning round before painting.

painted the block to red :D

will do one more round tomorrow.

very nice!

pistons were full carbon deposits so I made piston soup :p :D

got the shift rail fixed and smoothed the inner side of shift fork in Jyvaskyla.

now it looks totally fine.

recovered the pictures from phone.

Nice clean pistons. What solvent you used in piston soup?