1994 JEEP CHEROKEE battery

number of chain pins between the timing marks of
both sprockets. There must be 15 pins.
(6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket preload bolt to
108 Nzm (80 ft. lbs.) torque.
(8) Check the valve timing.
(9) Lubricate the tension spring, the thrust pin
and the pin bore in the preload bolt with Mopar En-
gine Oil Supplement, or equivalent. Install the
spring and thrust pin in the preload bolt head.
(10) 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 oil pan
and cylinder block.
(11) Position the timing case cover on the oil pan
gasket and the cylinder block.
(12) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 13).
(13) Install the timing case cover-to-cylinder block
bolts. Install the oil pan-to-timing case cover bolts.
(14) 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.
(15) Remove the cover alignment tool and install a
replacement oil seal into the cover.
(16) Install the vibration damper on the crank-
shaft.(17) Lubricate and tighten the damper bolt to 108
Nzm (80 ft. lbs.) torque.
(18) 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.
(19) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(20) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(21) Install the fan and shroud.
(22) 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 exhaust
manifold.
(5) Disconnect the exhaust hanger at the catalytic
converter and lower the pipe.
(6) Remove the starter motor.
(7) Remove the engine flywheel/transmission
torque converter housing access cover.
(8) If equipped with an oil level sensor, disconnect
the sensor.
(9) Position a jack stand directly under the engine
vibration damper.
(10) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(11) Remove the engine mount through bolts.
Fig. 12 Verify Crankshaft/Camshaft
InstallationÐTypical
Fig. 13 Timing Case Cover Alignment and Seal
Installation Tool 6139
9 - 72 4.0L ENGINEJ

(12) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(13) Remove the oil pan bolts. Carefully slide the
oil pan and gasket to the rear. If equipped with an
oil level sensor, take care not to damage the sensor.
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. If equipped with an oil level sensor, take
care not to damage the sensor.
(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) If equipped with an oil level sensor, connect
the sensor.
(11) Install the engine flywheel/transmission
torque converter housing access cover.
(12) Install the engine starter motor.
(13) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(14) Install the oil pan drain plug (Fig. 3). Tighten
the plug to 34 Nzm (25 ft. lbs.) torque.
(15) Lower the vehicle.
(16) Connect negative cable to battery.
(17) 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.
(18) Start the engine and inspect for leaks.
OIL PUMP
A gear-type oil pump is mounted at the underside
of the cylinder block opposite the No.4 main bearing.
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
(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.
Fig. 1 Fabrication of Alignment Dowels
Fig. 2 Position of Dowels in Cylinder Block
Fig. 3 Position of 5/16 inch Oil Pan Bolts
J4.0L ENGINE 9 - 73

CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(3) Use a piston ring compressor to install the con-
necting rod and piston assemblies through the top of
the cylinder bores (Fig. 18).
(4) Ensure the arrow on the piston top points to
the front of the engine (Fig. 18).
(5) Raise the vehicle.
Each bearing insert is fitted to its respective jour-
nal to obtain the specified clearance between the
bearing and the journal. In production, the select fit
is obtained by using various-sized, color-coded bear-
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
The rod journal is identified during the engine pro-
duction by a color-coded paint mark on the adjacent
cheek or counterweight toward the flange (rear) end
of the crankshaft. The color codes used to indicate
journal sizes are listed in the Connecting Rod Bear-
ing Fitting Chart.
When required, upper and lower bearing inserts of
different sizes may be used as a pair (refer to Con-
necting Rod Bearing Fitting Chart). A standard size
insert is sometimes used in combination with a 0.025
mm (0.001 inch) undersize insert to reduce clearance
0.013 mm (0.0005 inch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a ma-
chined surface adjacent to the oil squirt hole that
faces the camshaft side of the cylinder block.
(6) Install the connecting rod bearing caps and in-
serts in the same positions as removed.CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(7) Install the oil pan and gaskets as outlined in
the installation procedure.
(8) Lower the vehicle.
(9) Install the engine cylinder head, push rods,
rocker arms, bridges, pivots and engine cylinder head
cover.
(10) Fill the crankcase with engine oil.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the spark plugs.
(3) Raise the vehicle.
(4) Remove the oil pan and oil pump.
(5) Remove only one main bearing cap and lower
insert at a time (Fig. 1).
(6) Remove the lower insert from the bearing cap.
(7) Remove the upper insert by LOOSENING (DO
NOT REMOVE) all of the other bearing caps. Now
insert a small cotter pin tool in the crankshaft jour-
nal oil hole. Bend the cotter pin as illustrated to fab-
ricate the tool (Fig. 2). With the cotter pin tool in
place, rotate the crankshaft so that the upper bear-
ing insert will rotate in the direction of its locking
tab. Because there is no hole in the No.3 main jour-
nal, use a tongue depressor or similar soft-faced tool
to remove the bearing insert (Fig. 2). After moving
Fig. 18 Rod and Piston Assembly Installation
Fig. 1 Removing Main Bearing Caps and Lower
Inserts
9 - 80 4.0L ENGINEJ

(8) Check crankshaft end play. Crankshaft end
play is controlled by the thrust bearing which is
flange and installed at the No.2 main bearing posi-
tion.
(a) Attach a magnetic base dial indicator to the
cylinder block at either the front or rear of the en-
gine.
(b) Position the dial indicator rod so that it is
parallel to the center line of the crankshaft.
(c) Pry the crankshaft forward, position the dial
indicator to zero.
(d) Pry the crankshaft forward and backward.
Note the dial indicator readings. End play is the
difference between the high and low measurements
(Fig. 6). Correct end play is 0.038-0.165 mm
(0.0015-0.0065 inch). The desired specifications are
0.051-0.064 mm (0.002-0.0025 inch).
(e) If end play is not within specification, inspect
crankshaft thrust faces for wear. If no wear is ap-
parent, replace the thrust bearing and measure end
play. If end play is still not within specification, re-
place the crankshaft.
If the crankshaft was removed, install the crank-
shaft into the cylinder block (refer to Cylinder Block -
Assemble).
(9) Install the oil pan.
(10) Install the drain plug. Tighten the plug to 34
Nzm (25 ft. lbs.) torque.
(11) Lower the vehicle.
(12) Install the spark plugs. Tighten the plugs to
37 Nzm (27 ft. lbs.) torque.
(13) Fill the oil pan with engine oil to the full
mark on the dipstick level.
(14) Connect negative cable to battery.
REAR MAIN OIL SEALS
The crankshaft rear main bearing oil seal consists
of two half pieces of viton with a single lip that ef-fectively seals the rear of the crankshaft. Replace the
upper and lower seal halves as a unit to ensure leak-
free operation.
REMOVAL
(1) Remove the engine flywheel or converter drive
plate.
(2) Remove the oil pan.
(3) Remove the rear main bearing cap (No.7).
(4) Push the upper seal out of the groove. Ensure
that the crankshaft and seal groove are not damaged.
(5) Remove the lower half of the seal from the
bearing cap.
INSTALLATION
(1) Wipe the seal surface area of the crankshaft
until it is clean.
(2) Apply a thin coat of engine oil.
(3) Coat the lip of the seal with engine oil.
(4) Carefully position the upper seal into the
groove in the cylinder block. The lip of the seal faces
toward the front of the engine.
(5) Place the lower half of the seal into bearing cap
No.7 (Fig. 7).
(6) Coat the outer curved surface of the lower seal
with soap and the lip of the seal with engine oil (Fig.
7).
(7) Position the lower seal into the bearing cap re-
cess and seat it firmly. Be sure the seal is flush with
the cylinder block pan rail.
(8) Apply Loctite 515, or equivalent on the rear
bearing cap (Fig. 8). The bead should be 3 mm (0.125
in) thick. DO NOT apply Loctite 515, or equivalent
to the lip of the seal.
Fig. 7 Rear Main Bearing Oil Seal
Fig. 6 Crankshaft End Play Measurement
9 - 84 4.0L ENGINEJ

(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

(1) Disconnect the battery negative cable.
(2) Disconnect all wire harness connectors that
connect body wire harnesses to the frame wire har-
nesses.
(3) Loosen the clamps and disconnect the fuel
hoses from the filler nozzle (Fig. 16).
(4) Disconnect the parking brake cable.
(5) Support the exhaust system and disconnect the
support hangers.
(6) Disconnect all suspension components from the
body.
(7) Disconnect all drive train components from the
body.(8) Disconnect all steering components from the
body.
(9) Disconnect all engine control components from
the body.
(10) Disconnect all cooling system components
from the body.
(11) Disconnect all brake system components from
the body.
(12) Disconnect all remaining component connec-
tions between the body and the frame.
(13) Remove bolts from the frame and body. The
bolts are accessible from the underside of the frame
at the following locations:
²at the rear of each frame rail;
²at each rear quarter crossmember wedge;
²at the side of each frame rail and
²at the center of the front crossmember.
(14) Identify, mark and retain the attaching hard-
ware for installation reference.
(15) Remove the body from the frame.
INSTALLATION
(1) Position body on the frame.
(2) Install the body-to-frame attaching hardware.
(3) Connect the exhaust hangers, fuel tank hoses
and parking brake cable.
(4) Connect all the wire harness connectors.
(5) Connect all disconnected vehicle components to
the body. Refer to the applicable procedures within
this manual.
(6) Connect the battery negative cable.
Fig. 16 Fuel Hoses & Clamps
13 - 20 FRAME AND BUMPERSJ