1994 JEEP CHEROKEE torque

a time, to avoid damaging the bridges.
(3) Remove the push rods.
(4) Remove the tappets through the push rod open-
ings in the cylinder head with Hydraulic Valve Tap-
pet Removal/Installation Tool C-4129-A (Fig. 13).
CLEANING
Clean each tappet assembly in cleaning solvent to
remove all varnish, gum and sludge deposits.
INSPECTION
Inspect for indications of scuffing on the side and
base of each tappet body.
Inspect each tappet base for concave wear with a
straightedge positioned across the base. If the base is
concave, the corresponding lobe on the camshaft is
also worn. Replace the camshaft and defective tap-
pets.
LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 14).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Leak-Down
Tester 7980.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di-
ameter ball bearing on the plunger cap of the tappet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. DO NOT tighten
the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal po-
sition.
(6) Adjust the nose of the ram to align the pointer
with the SET mark on the scale of the tester and
tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the
base of the tester clockwise one revolution every 2
seconds.
(9) Observe the leak-down time interval from the
instant the pointer aligns with the START mark on
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-
110 seconds to leak-down. Discard tappets with leak-
down time interval not within this specification.
INSTALLATION
It is not necessary to charge the tappets with en-
gine oil. They will charge themselves within a very
short period of engine operation.
(1) Dip each tappet in Mopar Engine Oil Supple-
ment, or equivalent.
(2) Use Hydraulic Valve Tappet Removal/Installa-
tion Tool C-4129-A to install each tappet in the same
bore from where it was originally removed.
(3) Install the push rods in their original locations.
(4) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(5) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(6) Pour the remaining Mopar Engine Oil Supple-
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
Fig. 13 Hydraulic Valve Tappet Removal/Installation
Tool C-4129-A
Fig. 14 Leak-Down Tester 7980
J2.5L ENGINE 9 - 25

least 1 600 km (1,000 miles). The oil supplement
need not be drained until the next scheduled oil
change.
(7) Install the engine cylinder head cover.
VALVE TIMING
Disconnect the spark plug wires and remove the
spark plugs.
Remove the engine cylinder head cover.
Remove the capscrews, bridge and pivot assembly,
and rocker arms from above the No.1 cylinder.
Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
Rotate the crankshaft until the No.4 piston is at
top dead center (TDC) on the compression stroke.
Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90É.
Install a dial indicator on the end of the No.1 cyl-
inder intake valve push rod. Use rubber tubing to se-
cure the indicator stem on the push rod.
Set the dial indicator pointer at zero.
Rotate the crankshaft clockwise (viewed from the
front of the engine) until the dial indicator pointer
indicates 0.305 mm (0.012 inch) travel distance (lift).
The timing notch index on the vibration damper
should be aligned with the TDC mark on the timing
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
the camshaft because of pin failure. A spring pin is
available for service replacement.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt and fan
shroud.
(3) Remove the vibration damper retaining bolt
and washer.
(4) Use Vibration Damper Removal Tool 8068 to
remove the damper from the crankshaft (Fig. 1).
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in position, align the keyway on the vi-
bration damper hub with the crankshaft key and tap
the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and
washer.
(3) Tighten the damper retaining bolt to 108 Nzm
(80 ft. lbs.) torque.(4) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys-
tems for the proper specifications and procedures).
(5) Connect negative cable to battery.
TIMING CASE COVER OIL SEAL REPLACEMENT
This procedure is done with the timing case cover
installed.
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt.
(3) Remove the vibration damper.
(4) Remove the radiator shroud.
(5) Carefully remove the oil seal (Fig. 2). Make
sure seal bore is clean.
(6) Position the replacement oil seal on Timing
Case Cover Alignment and Seal Installation Tool
6139 with seal open end facing inward. Apply a light
film of Perfect Seal, or equivalent, on the outside di-
ameter of the seal. Lightly coat the crankshaft with
engine oil.
(7) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal In-
stallation Tool 6139 (Fig. 3). Tighten the nut against
the tool until it contacts the cover.
Fig. 1 Vibration Damper Removal Tool 8068
Fig. 2 Timing Case Cover Oil Seal Removal
9 - 26 2.5L ENGINEJ

(8) Remove the tools. Apply a light film of engine
oil on the vibration damper hub contact surface of
the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(10) Install the serpentine belt and tighten to the
specified tension (refer to Group 7, Cooling Systems
for the proper specifications and procedures).
(11) Install the radiator shroud.
(12) Connect negative cable to battery.
TIMING CASE COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Fig. 4).
(3) Remove the fan and hub assembly and remove
the fan shroud.
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and
generator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 4).
CLEANING
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
INSTALLATION
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward
the inside of the cover. Support the cover at the seal
area while installing the seal. Force it into position
with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
(3) Position the timing case cover on the oil pan
gasket and the cylinder block.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 5).
(5) Install the timing case cover-to-cylinder block
and the oil pan-to-timing case cover bolts.
(6) Tighten the 1/4 inch cover-to-block bolts to 7
Nzm (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 Nzm (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 14 Nzm
(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 Nzm (156 in. lbs.) torque.
(7) Remove the cover alignment tool.
Fig. 3 Timing Case Cover Oil Seal InstallationFig. 4 Timing Case Cover Components
Fig. 5 Timing Case Cover Alignment and Seal
Installation Tool 6139
J2.5L ENGINE 9 - 27

(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(10) Install the A/C compressor (if equipped) and
generator bracket assembly.
(11) Install the engine fan and hub assembly and
shroud.
(12) Install the serpentine drive belt and tighten to
obtain the specified tension.
(13) Connect negative cable to battery.
TIMING CHAIN AND SPROCKETS
The timing chain tensioner reduces noise and pro-
longs timing chain life. In addition, it compensates
for slack in a worn or stretched chain and maintains
the correct valve timing.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud.
(3) Remove the serpentine drive belt.
(4) Remove the crankshaft vibration damper.
(5) Remove the timing case cover.
(6) Rotate crankshaft until the ``0'' timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 6).
(7) Remove the oil slinger from the crankshaft.
(8) Remove the camshaft retaining bolt and re-
move the sprockets and chain as an assembly (Fig.
7).
(9) To replace the timing chain tensioner, the oil
pan must be removed.
INSTALLATION
(1) Turn the tensioner lever to the unlocked (down)
position (Fig. 8).
(2) Pull the tensioner block toward the tensioner
lever to compress the spring. Hold the block and turn
the tensioner lever to the lock position (Fig. 8).
(3) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in the crankshaft keyway, install the
crankshaft/camshaft sprockets and timing chain. En-
sure the timing marks on the sprockets are properly
aligned (Fig. 6).
(4) Install the camshaft sprocket retaining bolt and
washer. Tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
sprocket timing mark as shown in Fig. 9. Count the
number of chain pins between the timing marks of
both sprockets. There must be 20 pins.
(6) Turn the chain tensioner lever to the unlocked
(down) position (Fig. 8).
Fig. 6 Crankshaft/Camshaft Alignment
Fig. 7 Camshaft and Crankshaft Sprockets and
Chain
Fig. 8 Loading Timing Chain Tensioner
9 - 28 2.5L ENGINEJ

(7) Install the oil slinger.
(8) Replace the oil seal in the timing case cover.
(9) Install the timing case cover and gasket.
(10) With the key inserted in the keyway in the
crankshaft, install the vibration damper, washer and
bolt. Lubricate and tighten the bolt to 108 Nzm (80
ft. lbs.) torque.
(11) Install the fan and shroud.
(12) Connect negative cable to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. RE-
LEASE THE PRESSURE BEFORE REMOVING THE
DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Disconnect negative cable from battery.
(2) Drain the cooling system. DO NOT waste reus-
able coolant. If the solution is clean, drain it into a
clean container for reuse.
(3) Remove the radiator or radiator/condenser, if
equipped with A/C (refer to Group 7, Cooling System
for the proper procedure).
(4) Scribe a mark on the distributor housing in
line with the lip of the rotor.
(5) Scribe a mark on the distributor housing near
the clamp and continue the scribe mark on the cyl-
inder block in line with the distributor mark.
(6) For ease of installation, note the position of the
rotor and distributor housing in relation to adjacent
engine components.
(7) Remove the distributor and ignition wires.(8) Remove the engine cylinder head cover.
(9) Remove the rocker arms, bridges and pivots.
(10) Remove the push rods.
(11) Remove the hydraulic valve tappets from the
engine cylinder head.
(12) Remove the vibration damper.
(13) Remove the timing case cover.
(14) Remove the timing chain and sprockets.
(15) Remove the camshaft (Fig. 10).
INSPECTION
Inspect the cam lobes for wear.
Inspect the bearing journals for uneven wear pat-
tern or finish.
Inspect the bearings for wear.
Inspect the distributor drive gear for wear.
If the camshaft appears to have been rubbing
against the timing case cover, examine the oil pres-
sure relief holes in the rear cam journal. The oil
pressure relief holes must be free of debris.
INSTALLATION
(1) Lubricate the camshaft with Mopar Engine Oil
Supplement, or equivalent.
(2) Carefully install the camshaft to prevent dam-
age to the camshaft bearings (Fig. 10).
(3) Install the timing chain, crankshaft sprocket
and camshaft sprocket with the timing marks
aligned.
(4) Install the camshaft sprocket retaining bolt and
washer. Tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(5) Install the timing case cover with a replace-
ment oil seal (Fig. 11). Refer to Timing Case Cover
Installation.
(6) Install the vibration damper.
(7) Install the hydraulic valve tappets.
(8) Install the push rods.
(9) Install the rocker arms, bridges and pivots.
(10) Install the engine cylinder head cover.
(11) Install the distributor and ignition wires.
Fig. 9 Verify Sprocket/Chain Installation
Fig. 10 Camshaft
J2.5L ENGINE 9 - 29

INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install the camshaft sprocket, crankshaft
sprocket and timing chain with the timing marks
aligned (Fig. 15).
(5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
sprocket timing mark as shown in Fig. 17. Count the
number of chain pins between the timing marks of
both sprockets. There must be 20 pins.
(6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket bolt to 108 Nzm
(80 ft. lbs.) torque.
(8) Check the valve timing.
(9) Coat both sides of the replacement timing case
cover gasket with gasket sealer. Applya3mm(1/8
inch) bead of Mopar Silicone Rubber Adhesive Seal-
ant, or equivalent to the joint formed at the timing
case cover and cylinder block.
(10) Position the timing case cover on the oil pan
gasket and the cylinder block.
(11) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening of
the cover (Fig. 18).
(12) Install the timing case cover-to-cylinder block
bolts. Install the oil pan-to-timing case cover bolts.
(13) Tighten the 1/4 inch cover-to-block bolts to 7
Nzm (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 Nzm (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 14 Nzm(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 Nzm (156 in. lbs.) torque.
(14) Remove the cover alignment tool and install a
replacement oil seal into the cover.
(15) Install the vibration damper on the crank-
shaft.
(16) Lubricate and tighten the damper bolt to 108
Nzm (80 ft. lbs.) torque.
(17) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive
belt idler pulley.
(b) Install the generator.
(c) Install the A/C condenser and receiver/drier
assembly.
(18) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(19) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(20) Install the fan and shroud.
(21) Connect negative cable to battery.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Remove the oil pan drain plug and drain the
engine oil.
(4) Disconnect the exhaust pipe at the engine ex-
haust manifold.
(5) Disconnect the exhaust hanger at the catalytic
converter and lower the pipe.
(6) Remove the engine starter motor.
(7) Remove the flywheel/torque converter housing
access cover.
(8) Position a jack stand directly under the engine
vibration damper.
Fig. 17 Verify Crankshaft/Camshaft Installation
Fig. 18 Timing Case Cover Alignment and Seal
Installation Tool 6139
9 - 32 2.5L ENGINEJ

(9) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(10) Remove the engine mount through bolts.
(11) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(12) Remove the oil pan bolts. Carefully remove
the oil pan and gasket.
CLEANING
Clean the block and pan gasket surfaces.
INSTALLATION
(1) Fabricate 4 alignment dowels from 1 1/2 x 1/4
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier in-
stallation and removal with a screwdriver (Fig. 1).
(2) Install two dowels in the timing case cover. In-
stall the other two dowels in the cylinder block (Fig.
2).
(3) Slide the one-piece gasket over the dowels and
onto the block and timing case cover.
(4) Position the oil pan over the dowels and onto
the gasket.(5) Install the 1/4 inch oil pan bolts. Tighten these
bolts to 14 Nzm (120 in. lbs.) torque. Install the 5/16
inch oil pan bolts (Fig. 3). Tighten these bolts to 18
Nzm (156 in. lbs.) torque.
(6) Remove the dowels. Install the remaining 1/4
inch oil pan bolts. Tighten these bolts to 14 Nzm (120
in. lbs.) torque.
(7) Lower the engine until it is properly located on
the engine mounts.
(8) Install the through bolts and tighten the nuts.
(9) Lower the jack stand and remove the piece of
wood.
(10) Install the flywheel/torque converter housing
access cover.
(11) Install the engine starter motor.
(12) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(13) Install the oil pan drain plug (Fig. 3). Tighten
the plug to 34 Nzm (25 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect negative cable to battery.
(16) Fill the oil pan with engine oil to the specified
level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(17) Start the engine and inspect for leaks.
OIL PUMP
The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a
gear on the camshaft. Oil is siphoned into the pump
through an inlet tube and strainer assembly that is
pressed into the pump body.
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
Fig. 1 Fabrication of Alignment Dowels
Fig. 2 Position of Dowels in Cylinder Block
Fig. 3 Position of 5/16 inch Oil Pan Bolts
J2.5L ENGINE 9 - 33

(75 psi). In the relief position, the valve permits oil
to bypass through a passage in the pump body to the
inlet side of the pump.
Oil pump removal or replacement will not affect
the distributor timing because the distributor drive
gear remains in mesh with the camshaft gear.
REMOVAL
(1) Drain the engine oil.
(2) Remove the oil pan.
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
4).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer as-
sembly must be installed to assure an airtight seal.
INSTALLATION
(1) Install the oil pump on the cylinder block using
a replacement gasket. Tighten the short bolt to 14
Nzm (10 ft. lbs.) torque and the long bolt to 23 Nzm
(17 ft. lbs.) torque.
(2) Install the oil pan.
(3) Fill the oil pan with oil to the specified level.
OIL PUMP PRESSURE
The MINIMUM oil pump pressure is 89.6 kPa (13
psi) at 600 rpm. The MAXIMUM oil pump pressure
is 255-517 kPa (37-75 psi) at 1600 rpm or more.
PISTONS AND CONNECTING RODS
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the rocker arms, bridges and pivots.
(3) Remove the push rods.
(4) Remove the engine cylinder head.
(5) Position the pistons one at a time near the bot-
tom of the stroke. Use a ridge reamer to remove the
ridge from the top end of the cylinder walls. Use a
protective cloth to collect the cuttings.
(6) Raise the vehicle.
(7) Drain the engine oil.
(8) Remove the oil pan and gasket.
(9) Remove the connecting rod bearing caps and
inserts. Mark the caps and rods with the cylinder
bore location. The connecting rods and caps are
stamped with a two letter combination (Fig. 1).
(10) Lower the vehicle until it is about 2 feet from
the floor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assistant push the piston/connecting
rod assemblies up and through the top of the cylinder
bores (Fig. 2).
INSPECTIONÐCONNECTING ROD
CONNECTING ROD BEARINGS
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Figs. 3 and 4). Check the bear-
ings for normal wear patterns, scoring, grooving, fa-
tigue and pitting (Fig. 5). Replace any bearing that
shows abnormal wear.
Fig. 4 Oil Pump Assembly
Fig. 1 Stamped Connecting Rods and Caps
9 - 34 2.5L ENGINEJ