Diesel XJ Cherokee Chief

1985 Jeep XJ Cherokee Chief Diesel
List sticker price $18,657 (1985)
Renault 2.1L (126cu.in.) SOHC Intercooled Turbocharged Diesel J8S
85hp@3750rpm  132tq@2750rpm  T2 turbo  CR-21.5:1  10-12 pounds boost
5 head bolts/studs per cylinder,  'interference' head 86mm x 89mm (3.39" x 3.5")
5 speed manual AX5 21 spline   4WD   4 door   NP207 T-case Stock tires 215/75 15
RARE,  ? 1 of 30-50 in US (including MJ)
0-62mph 22.3 seconds Max speed 88mph

Renault Engine
2.1L Intercooled Turbo Diesel J8S 'Douvrin' family of engines
Bosch EPVE Fuel Injection Bosch No. 0460 494 160 Vehicle Model VE4/9F2200R183
Garrett T2 Turbocharger TAO 216 #466452-1 (Winnebago TAO 305 #465764-1 AR=0.36)
air to air intercooler
Single Overhead Cam 2 valve/cylinder
Cast Aluminum block
Ricardo Comet 5 pattern aluminum head
2065cc
86mmx89mm bxs (3.39"x3.50")
21.5:1cr
1-3-4-2 firing order (#1 against firewall)
Forged steel crank
5 main bearings
Warm weather = number 2-D fuel
Cold weather = number 1-D fuel
5.0-5.5 qt engine oil capacity
9 qt (8.5L) cooling

Why?
-Preserve a bit of XJ history
-one of the rarest of XJs- 2.1L Diesel, Cherokee Chief, 4WD, 5 speed
-something different, very different
-better mileage, average 28-30mpg and up to 35mpg highway
-because the Renault 2.1 diesel is not a 'darling' engine
-because...'Diesel XJ'

PARTS AVAILABLE FOR SALE
-Rocker Arms, 8 avaliable, full set only
-Glow Plugs, 4 available, full set only
-Starter, rebuild
-Alternator, rebuild

Plan- Keep it stock but reliable, freeway driver, 35mpg!

TO DO LIST-
-clean
-change trans fluid, front diff fluid,  rear diff, transfer case, radiator, engine
-fix thermostat housing leak and the radiator cap leak

-replace motor mounts passenger side and drivers side
-get the emergency brake working, intermediate cable replace
-install rear bump stops
-fix the few rust spots
-repaint and letter the 'Cherokee Chief'
-repaint black around side windows
-compound, buff and wax the paint
-paint and undercoat the underside
-replace all universal joints- front axle(passenger side bad), front DS, rear DS
-replace front upper and lower control arms (bad bushings)
-fix all the little things which are found during ownership-grease window regulators, replace window crank

DONE-
 Install Fuel tank strainer/sock, Airtex FS198
 Replace fuel filler neck hose, NAPA NBH 1031
-fix steering wheel column wobble, fix horn button
-rebuild injector pump, install
-replace the glow plugs
-replace the starter
-?rebuild injectors, cleaned
-Fix fuel system? back flush supply line and return line, bypass/isolate fuel system
-check injectors for compression back flow, ?bad check valve in injector
-buy and install rear bumper, brackets and end caps
-mount and balance new General Grabber AT2 tires
-front end alignment
-replace adj track bar with new stock replacement track bar
-replace the 31" tires and rims, with stock 'turbine' rims and 27.4" tires General Grabber AT2 225/70R15
-remove the lift kit and return to stock height F+ R
-check the brakes, replace F+ R brakes
-inspection and registration
-fix the broken rocker arms and get it running
-fuel cleaner, fuel filter/separator
-Upgrade the headlights not needed
-replace failed alternator
-check the hoses, belts, steering 
-drop fuel tank- clean out, fix leak, check that draw tube is at bottom
 flasher relays, radio, fuel cutoff valve wire
-adjust the Cold Start mechanism
-replace front driveshaft
-check the diff ratios, make sure they match, install front drive shaft

PARTS-
-Radiator cap- Stant 10203
-Front axle U-Joints- Moog 378
-Front and Rear Drive shaft U-Joints- MOOG 280
-Timing Belt and Adjuster- Gates K035040 (don't need additional pulley in K045040)
-Valve Cover Gasket- Victor Reinz VS50031
-Belts- Gates 7270 alternator, Gates 7330 power steering, Gates 9380 A/C compressor
-Battery- Duracell Group 34  1020CA/850CCA@0*F   7"x10.75"x8"tall
-Oil Filter- Bosch 3401
-Alternator- AutoZone #14892 (not 14894)
-Fuel Filter/Separator- AC Delco TP1006
-brakes- rotors, pads, shoes, spring kit, adjuster, brake cylinder  -all RockAuto
-front springs- stock height progressive Moog  -RockAuto
-control arms- upper and lower with bushings Moog  -RockAuto
-rear leaf springs- stock height Dorman 929-301 -RockAuto
-K & N air filter E-2402
-Rocker Arms- RockAuto european market before 1994, Renault 1988 Trafic 2.1L L4 Diesel rocker arm BGA #RA4693 J8S engine and others $19.32 each
-Fuel Shut Off Solenoid Bosch 0330001015
-Miller Diesel, Harrisburg PA 717-545-5931 Great resource, can rebuild the Injector pump and service the injectors

TIRES-
General Grabber AT2     Wal-Mart-best price
205/75x15=27.1" 8.0" 24.3lbs $105.00
215/75x15=27.7" 8.5" 28.5lbs $95.24
225/70x15=27.4" 9.0" 30.5lbs $100.72  -ORDERED and INSTALLED
235/75x15=28.9" 9.3" 33.6lbs $116.45
255/70x15=29.1" 10"  39.0lbs $101.58
Dunlop GrandTec 225/70x15=27.2" ?not available  $88 Sam's
BFG AllTerrain (smallest)215/75x15=27.8" 8.4" 33lbs $138   235/75x15=29.0" 9.1" 36lbs $156.63 Sam's
GoodYear DuraTrac (smallest)235/75x15=28.9" 9.3" 36lbs $181 Sam's




Collecting any and all information on this vehicle

http://www.matrasport.dk/Cars/Espace/vault/J63/MRmotj8s.pdf
http://jeep-manual.ru/index.php?page=143

Rob from ComancheClub.com writes-
 I imagine that the OP must have had the belt come off when doing the water pump and put it back on in the right place. Zombie, it doesn't sound like you had any business in there and I think you now know that. Hopefully, the god-knows-how-old-belt was the weak point. The rockers are made to snap off in the case of contact from mistiming (This is an interference motor, you made the valves kiss the piston). Pull the valve cover and see if any rockers are snapped or valves bent. Once you are sure that everything seems in place... First things first, you need a new belt kit. The new kit comes with an improved belt tension assembly, so you would be better off.









Mine...THE BAD-

Clogged 'GAS' in tank fuel filter/sock

Fuel Tank Pickup Tube