1994 JEEP CHEROKEE Service Repair Manual

red. Remove the exhaust tailpipe/muffler clamp and
twist the exhaust tailpipe out of the muffler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe hanger. Make sure that
the exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front ex-
haust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-catalytic
converter clamp to 61 Nzm (45 ft. lbs.) torque (Fig.
6). Tighten the nuts on the rear exhaust tailpipe
clamp to 14 Nzm (10 ft. lbs.) torque (Fig. 7).
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐYJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are clamped together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the exhaust tailpipe hanger/bracket
(Fig. 9).
(4) Remove the exhaust tailpipe from the front ex-
haust tailpipe hanger (Fig. 10).
(5) Heat the converter-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red.
(6) While the metal is still cherry red, place a
block of wood against the front of the muffler and
drive the muffler rearward to disengage.
(7) Remove the exhaust tailpipe/muffler assembly.
(8) Remove the exhaust tailpipe from the muffler:
²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, remove the exhaust tailpipe/muffler clamp.
Heat the exhaust tailpipe-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red. While the metal is still cherry red, twist the ex-
haust tailpipe out of the muffler.
INSTALLATION
(1) Install the muffler onto the catalytic converter
outlet. Ensure that the locator on the converter
aligns with the notch on the muffler, if so equipped.
Install the clamp and tighten the nuts finger tight.
Fig. 8 Front Exhaust Tailpipe Hanger
Fig. 9 Rear Exhaust Tailpipe Hanger/Bracket
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

(2) Install the exhaust tailpipe into the muffler
outlet. Ensure that the locator on the exhaust
tailpipe aligns with the notch on the muffler, if so
equipped. Install the clamp and tighten the nuts fin-
ger tight.
(3) Install the front exhaust tailpipe supports and
the rear exhaust tailpipe hanger. Ensure that the ex-
haust tailpipe has sufficient clearance from the floor
pan and shields.
(4) Tighten the nuts on the muffler-to-catalytic
converter and the muffler-to-exhaust tailpipe clamps
to 61 Nzm (45 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and contact with the body panels and shields.
ENGINE EXHAUST MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove all components attached to the intake
manifold.
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 11).
(7) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 11).
CLEANING
Clean the intake and engine exhaust manifolds
and cylinder head mating surfaces.DO NOT allowforeign material to enter either the intake mani-
fold or the ports in the cylinder head.
INSTALLATION
(1) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(2) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located over
the end studs and spacer (Fig. 11).
(3) Tighten bolt No.1 to 41 Nzm (30 ft. lbs.) torque
(Fig. 11).
(4) Install the intake manifold on the cylinder
head dowels (Fig. 11).
(5) Install bolts 2 through 5 (Fig. 11). Tighten
these bolts to 31 Nzm (23 ft. lbs.) torque.
(6) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 11).
(7) Tighten nuts 6 and 7 to 31 Nzm (23 ft. lbs.)
torque (Fig. 11).
(8) Install all components to the intake manifold.
(9) Raise the vehicle.
(10) Connect the exhaust pipe to the engine ex-
haust manifold. Tighten the bolts to 31 Nzm (23 ft.
lbs.) torque.
(11) Lower the vehicle.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
ENGINE EXHAUST MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The manifolds use a common gasket at the cylinder
head.
Refer to Intake ManifoldÐ4.0L Engine in this sec-
tion for the proper removal and installation proce-
dures.
Fig. 10 Front Exhaust Tailpipe Hanger
Fig. 11 Intake/Engine Exhaust Manifold Installation
(2.5L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

INTAKE MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air inlet hose from the throttle
body and air cleaner.
(3) Loosen the accessory drive belt tension and re-
move the belt from the power steering pump.
(4) Remove the power steering pump and brackets
from the water pump and intake manifold. Support
power steering pump and bracket with mechanics
wire attached to the radiator upper crossmember.
(5) Remove the fuel tank filler cap to relieve the
fuel tank pressure.
(6) Install the fuel tank filler cap.
(7) Disconnect fuel supply and return tube from
the fuel rail (refer to Group 14, Fuel System - Quick
Connect Fittings).
(8) Disconnect the accelerator cable from the throt-
tle body and the holddown bracket.
CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Disconnect the electrical connectors. Pull the
harnesses away from the manifold.
²The throttle position sensor.
²The idle speed control motor.
²The coolant temperature sensor at the thermostat.
²The manifold air temperature sensor at the intake
manifold.
²The fuel injectors.
²The oxygen sensor.
(10) Disconnect the crankcase ventilation (CCV)
vacuum hose and manifold absolute pressure (MAP)
sensor vacuum hose connector at the intake mani-
fold.
(11) Disconnect vacuum hose from vacuum port on
the intake manifold.
(12) Disconnect CCV hose at the cylinder head
cover (Fig. 12).
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at
the intake manifold.
(15) Remove bolts 2 through 5 securing the intake
manifold to the cylinder head (Fig. 11). Slightly
loosen bolt No.1 and nuts 6 and 7.
(16) Remove the intake manifold and gaskets.
Drain the coolant from the manifold.
CLEANING
Clean the intake manifold and cylinder head mat-
ing surfaces.DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) Install the new intake manifold gasket over the
locating dowels.
(2) Position the manifold in place and finger
tighten the mounting bolts.
(3) Tighten the fasteners in sequence and to the
specified torque (Fig. 11).
²Fastener No.1ÐTighten to 41 Nzm (30 ft. lbs.)
torque.
²Fasteners Nos.2 through 7ÐTighten to 31 Nzm (23
ft. lbs.) torque.
(4) Connect the fuel return and supply tube to the
connector next to the fuel rail. Push them into the
fitting until a click is heard. Verify that the connec-
tions are complete.
²First, ensure only the retainer tabs protrude from
the connectors.
²Second, pull out on the fuel tubes to ensure they
are locked in place.
(5) Connect the molded vacuum hoses to the vac-
uum port on the intake manifold and the cylinder
head cover.
(6) Connect the electrical connectors.
²The throttle position sensor.
²The automatic idle speed control motor.
²The coolant temperature sensor at the thermostat
housing.
²The fuel injectors.
²The air manifold temperature sensor.
²The oxygen sensor.
(7) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttle body.
(8) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
(9) Connect the accelerator cable and cruise control
cable to the holddown bracket and the throttle arm.
Fig. 12 Crankcase Ventilation (CCV) Hose
(2.5L Engine)
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the wa-
ter pump to turn in the opposite direction resulting
in engine overheating. Refer to Group 7, Cooling
System for the proper procedure.
(10) Tension the accessory drive belt. Refer to
Group 7, Cooling System for the proper procedure.
(11) Connect the air inlet hose to the throttle body
and the air cleaner.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
INTAKE MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The two manifolds use a common gasket at the cyl-
inder head.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove air cleaner inlet hose from throttle
plate assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, cruise control cable (if
equipped) and the transmission line pressure cable.
(5) Disconnect all electrical connectors on the in-
take manifold.
(6) Disconnect and remove the fuel supply and re-
turn lines from the fuel rail assembly (refer to Group
14, Fuel System).
(7) Loosen the accessory drive belt (refer to Group
7, Cooling System). Loosen the tensioner.
(8) Remove the power steering pump and bracket
from the intake manifold and set aside.
(9) Remove the fuel rail and injectors (refer to
Group 14, Fuel System).
(10) Raise the vehicle.
(11) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal.
(12) Lower the vehicle.
(13) Remove the intake manifold and engine ex-
haust manifold.
CLEANING
Clean the mating surfaces of the cylinder head and
the manifold if the original manifold is to be installed.
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement manifold.
INSTALLATION
(1) Install a new exhaust/intake manifold gasket
over the alignment dowels on the cylinder head.
(2) Position the engine exhaust manifold to the
cylinder head. Install fastener No.3 and finger
tighten at this time (Fig. 13).
(3) Install intake manifold on the cylinder head
dowels.(4) Install washers and fasteners Nos.1, 2, 4, 5, 8,
9, 10 and 11 (Fig. 13).
(5) Install washers and fasteners Nos.6 and 7 (Fig. 13).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 13).
²Fasteners Nos.1 through 5ÐTighten to 33 Nzm (24
ft. lbs.) torque.
²Fasteners Nos.6 and 7ÐTighten to 31 Nzm (23 ft.
lbs.) torque.
²Fasteners Nos.8 through 11ÐTighten to 33 Nzm
(24 ft. lbs.) torque.
(7) Install the fuel rail and injectors.
(8) Install the power steering pump and bracket to the
intake manifold. Tighten the belt to specification. Refer
to Group 7, Cooling System for the proper procedures.
(9) Install the fuel supply and return lines to the
fuel rail assembly.Before connecting the fuel
lines to the fuel rail replace the O-rings in the
quick-connect fuel line couplings.Refer to Group
14, Fuel System for the proper procedure.
(10) Connect all electrical connections on the in-
take manifold.
(11) Connect the vacuum connector on the intake
manifold and install it in the bracket.
(12) Install throttle cable, cruise control cable (if
equipped).
(13) Install the transmission line pressure cable (if
equipped). Refer to Group 21, Transmission for the
adjustment procedures.
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the throttle plate as-
sembly.
(16) Raise the vehicle on a side mounted hoist.
(17) Using a new seal, connect the exhaust pipe to
the engine exhaust manifold. Tighten the bolts to 31
Nzm (23 ft. lbs.) torque.
(18) Lower the vehicle.
(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
Fig. 13 Intake/Engine Exhaust Manifold Installation
(4.0L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9

TORQUE SPECIFICATIONS
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

FRAME AND BUMPERS
CONTENTS
page page
XJ BUMPERS........................... 3
XJ UNIBODY CONSTRUCTION............. 1YJ BUMPERS AND FRAME ATTACHED
COMPONENTS........................ 14
YJ FRAME............................. 8
XJ UNIBODY CONSTRUCTION
INDEX
page page
Collision Damage Torque................... 1General Information........................ 1
GENERAL INFORMATION
JeeptXJ Vehicles (Fig. 1) and the cab section of
Jeeptare constructed as a unitized body and frame.
JeeptXJ unibodies are constructed from special
high-strength steel and coated metals. These types of
metals reduce weight and provide strength.
COLLISION DAMAGE TORQUE
DAMAGE DIAGNOSIS
A vehicle constructed as a unibody reacts differ-
ently to the impact of a collision. While the damageat the immediate point of impact is easily recogniz-
able, the damage must be diagnosed to expose it.
With unibody construction, there are five logical
areas to examine to expose damage.
(1) Damage at the immediate point of impactÐpri-
mary damage.
(2) The other (lessor) body damageÐsecondary
damage.
(3) Damage to the exterior trim and other surface-
attached components.
(4) Damage to the mechanical components.
(5) The interior trim and accessory damage.
DAMAGE REPAIR
A logical approach to the sequence of damage re-
pair must also be used. Usually, during vehicle re-
pair, the tasks are accomplished in the reverse order
of consequence.
When there is damage to a vehicle, the alignment
points must be returned too specifications. This en-
tails:
²accurate measurement;
²repetitive measurement; and
²re-check of measurements.
Collision damage repair can be completed ``right''
the first time:
²if the fundamental steps for collision damage re-
pair are correctly followed, and
²if the basic structural details of unibody construc-
tion are correctly considered.
Fig. 1 JeepTXJ
JFRAME AND BUMPERS 13 - 1

Fig. 2 Frame Alignment Reference DimensionsÐXJ Vehicles
13 - 2 FRAME AND BUMPERSJ

XJ BUMPERS
INDEX
page page
Front Bumper............................ 3
Front Tow Hooks......................... 5Rear Bumper............................ 6
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks
can be removed from XJ front bumpers with the
bumper attached to the vehicle. Do not remove the
bumper from the vehicle if only these components re-
quire service.
If equipped with a brush guard, refer to the
Brush Guard Removal within Group 23ÐBody
Components.
(2) If equipped, disconnect the fog lamp wire har-
ness connectors (Fig. 1).
(3) Disconnect the vacuum reservoir tube harness
connectors (Figs. 2 and 3).
(4) If equipped, remove the locknuts and Torx-head
bolts that attach the tow hook straps (Fig. 4) to the
underbody sillmember.
The retaining screws and the steering gear
skid plate must be removed before the left strap
can be removed from the sillmember.
(5) Detach the tow hook straps from the sillmem-
ber.
(6) Support the bumper.
(7) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers (Fig.
5).
(8) Remove the support and the bumper from the
vehicle. 5).(9) If equipped, remove the nuts and bolts that at-
tach the tow hooks to the bumper support brackets.
(10) Remove the support brackets (Fig. 6), bumper
guards (Fig. 7) and caps (Fig. 8) from the bumper
rail.
(11) Remove the license plate bracket (Fig. 9), if
equipped, from the bumper rail.
Fig. 1 Fog Lamp Wire Harness Connector
Fig. 2 Vacuum ReservoirÐLeft Side
Fig. 3 Vacuum ReservoirÐRight Side With Speed
Control Only
JFRAME AND BUMPERS 13 - 3