1994 JEEP CHEROKEE front

(4) Install the through bolt and the retaining nut
(Fig. 6). Tighten the through bolt nut to 65 Nzm (48
ft. lbs.) torque.
(5) Remove the engine support.
(6) Lower the vehicle.
(7) Connect negative cable to battery.
REMOVALÐYJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.(3) Support the engine.
(4) Remove through bolt nut (Fig. 9). DO NOT re-
move the through bolt.
(5) Remove the retaining bolts/nuts from the sup-
port cushions (Fig. 9).
(6) Remove the through bolt.
(7) Remove the engine support cushions.
Fig. 6 Front MountsÐXJ Vehicles
Fig. 7 Engine Support BracketÐRight Side
Fig. 8 Support Cushion BracketÐLeft Side
Fig. 9 Front MountsÐYJ Vehicles
J2.5L ENGINE 9 - 11

(a) Disconnect the power steering hoses from the
fittings at the steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign material from entering the
system.
(21) Disconnect the coolant hoses from the rear of
the intake manifold.
(22) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(23) Raise the vehicle.
(24) Remove the oil filter.
(25) Remove the starter motor.
(26) Disconnect the exhaust pipe from the exhaust
manifold.
(27) Remove the flywheel/converter housing access
cover.
(28) If equipped with an automatic transmission,
mark the converter and drive plate location in refer-
ence to each other and remove the converter-to-drive
plate bolts.(29) Remove the upper flywheel/converter housing
bolts and loosen the bottom bolts.
(30) Remove the engine support cushion-to-engine
compartment bracket bolts.
(31) Remove the engine shock damper bracket
from the sill.
(32) Lower the vehicle.
(33) Attach a lifting device to the engine.
(34) Raise the engine slightly off the front sup-
ports.
(35) Place a support stand under the converter or
flywheel housing.
(36) Remove the remaining bottom converter or
flywheel housing bolts.
(37) Lift the engine out of the engine compartment
and install on an engine stand.
(38) Install the oil filter to keep foreign material
out of the engine.
INSTALLATION
(1) Remove the oil filter.
(2) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(3) If equipped with a manual transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.
(c) Install and tighten the flywheel housing
lower bolts finger tight.
(4) If equipped with an automatic transmission:
Fig. 16 Heater Hoses (LH Drive Vehicles), Throttle
Linkage & Quick-Connect Fuel Lines
Fig. 17 Heater Hoses (RH Drive Vehicle)
Fig. 18 Air Cleaner and Power Steering Pump
J2.5L ENGINE 9 - 15

(7) Disconnect the wires at the starter motor sole-
noid and injection wire harness connector.
(8) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 20). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(9) Remove the fuel line bracket from the intake
manifold.
(10) Disconnect the engine ground strap.
(11) Remove the air cleaner assembly.
(12) Disconnect the vacuum purge hose at the fuel
vapor canister tee.
(13) Disconnect the idle speed actuator wire con-
nector.
(14) Disconnect the throttle cable and remove it
from the bracket.
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if
equipped.
(17) Disconnect the oxygen sensor wire connector.
(18) Disconnect the upper and lower radiator hoses
at the radiator.
(19) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(20) Disconnect the heater hoses.
(21) Remove the fan shroud screws.
(22) Remove the radiator attaching bolts.
(23) Remove the radiator and fan shroud.
(24) Remove the fan and spacer or Tempatrol fan
assembly.
(25) Install a 5/16 X 1/2-inch SAE capscrew
through fan pulley into water pump flange. This will
maintain the pulley and water pump in alignment
when crankshaft is rotated.
(26) Remove the power brake vacuum check valve
from the booster, if equipped.
(27) If equipped with power steering:(a) Disconnect the hoses from the fittings at the
steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the
system.
(28) Lift the vehicle and support it with support
stands.
(29) Remove the oil filter.
(30) Remove the starter motor.
(31) Remove the flywheel housing access cover.
(32) Remove the engine support cushion-to-bracket
through bolts.
(33) Disconnect the exhaust pipe from the mani-
fold.
(34) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(35) Remove the engine shock damper bracket
from the sill.
(36) Lower the vehicle.
(37) Attach a lifting device to the engine.
(38) Raise the engine off the front supports.
(39) Place a support stand under the flywheel
housing.
(40) Remove the remaining flywheel housing bolts.
(41) Lift the engine out of the engine compartment
and install on an engine stand.
(42) Install the oil filter to keep foreign material
out of the engine.
INSTALLATION
(1) Remove the oil filter.
(2) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(3) Insert the transmission shaft into the clutch
spline.
(4) Align the flywheel housing with the engine.
(5) Install and finger tighten the flywheel housing
lower bolts.
(6) Install the engine support cushions (if re-
moved).
(7) Remove the support stand from beneath the fly-
wheel housing.
(8) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten.
(9) Remove the engine lifting device.
(10) Raise the vehicle.
(11) Attach the engine shock damper bracket to
the sill.
(12) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(13) Install the flywheel housing access cover.
Fig. 20 Fuel Line Quick-Connect Couplings
J2.5L ENGINE 9 - 17

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

CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain the radiator. DO NOT waste reusable
coolant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
(4) Disconnect the radiator overflow tube, radiator
hoses, automatic transmission fluid cooler pipes (if
equipped).
(5) Remove the radiator.
(6) If equipped with air conditioning:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpentine drive
belt idler pulley.
(b) Disconnect and remove the generator.
(c) Remove the A/C condenser attaching bolts
and move the condenser and receiver/drier assem-
bly up and out of the way.
(7) Remove the serpentine drive belt.
(8) Remove the crankshaft vibration damper.
(9) Remove the timing case cover. Clean the gas-
ket material from the cover.
(10) Rotate crankshaft until the crankshaft
sprocket timing mark is closest to and on the center
line with the camshaft sprocket timing mark (Fig.
15).
(11) Remove camshaft sprocket retaining bolt.
(12) Remove the crankshaft oil slinger.
(13) Remove the sprockets and chain as an assem-
bly (Fig. 16).CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) Inspect the damaged camshaft pin.
(15) If the pin is a spring-type pin, remove the bro-
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.
(16) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: Cover the opened oil pan area to prevent
metal chips from entering the pan.
(17) Drill into the pin center witha4mm(5/32
inch) drill bit.
(18) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled, bab-
bitt-lined bearings that are pressed into the cylinder
block and then line reamed. The camshaft bearing
bores and bearing diameters are not the same size.
They are stepped down in 0.254 mm (0.010 inch) in-
crements from the front bearing (largest) to the rear
bearing (smallest). This permits easier removal and
installation of the camshaft. The camshaft bearings
are pressure lubricated.
It is not advisable to attempt to replace cam-
shaft bearings unless special removal and instal-
lation tools are available.
Camshaft end play is maintained by the load
placed on the camshaft by the oil pump and distrib-
utor drive gear. The helical cut of the gear holds the
camshaft sprocket thrust face against the cylinder
block face.
Fig. 15 Timing Chain Alignment
Fig. 16 Camshaft and Crankshaft Sprocket and
Chain
J2.5L ENGINE 9 - 31

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

Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
CONNECTING RODS
Misaligned or bent connecting rods can cause ab-
normal wear on pistons, piston rings, cylinder walls,
connecting rod bearings and crankshaft connecting
rod journals. If wear patterns or damage to any of
these components indicate the probability of a mis-
aligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe the oil from the connecting rod journal.(2) Use short rubber hose sections over rod bolts
during installation.
(3) Lubricate the upper bearing insert and install
in connecting rod.
(4) Use piston ring compressor to install the rod
and piston assemblies. The oil squirt holes in the
rods must face the camshaft. The arrow on the piston
crown should point to the front of the engine (Fig. 6).
Verify that the oil squirt holes in the rods face the
camshaft and that the arrows on the pistons face the
front of the engine.
(5) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of
Fig. 2 Removal of Connecting Rod and Piston
Assembly
Fig. 3 Connecting Rod Bearing Inspection
Fig. 4 Locking Tab Inspection
Fig. 5 Scoring Caused by Insufficient Lubrication or
by Damaged Crankshaft Pin Journal
Fig. 6 Rod and Piston Assembly Installation
J2.5L ENGINE 9 - 35