1994 JEEP CHEROKEE radiator cap

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

(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

(12) Properly position the distributor rotor as fol-
lows:
(a) Remove No.1 spark plug. Hold your finger
over the spark plug hole and rotate the crankshaft
until compression pressure is felt. Slowly continue
to rotate the crankshaft until the timing index on
the vibration damper aligns with the top dead cen-
ter (TDC) mark (0É on the timing degree scale).Al-
ways rotate the crankshaft clockwise (the
direction of normal rotation). DO NOT rotate
the crankshaft backward to align the timing
marks.
(b) Rotate the oil pump gear so that the gear slot
on the oil pump shaft is slightly past the 3 o'clock
position (Fig. 12). A flat blade screwdriver can be
used to rotate the gear.
(c) Turn the distributor shaft until the rotor tip
points in the direction of No.1 terminal in the dis-
tributor cap. Turn the rotor 1/8 turn counterclock-
wise past the position of No.1 terminal.
(d) With the distributor cap removed, start the
distributor into the cylinder block with the rotor lo-
cated at the 5 o'clock position (Fig. 13).
(e) Slide the distributor shaft down into the en-
gine. Position the distributor vacuum advance
mechanism housing in approximately the same lo-
cation as when removed. Align the scribe mark onthe distributor housing with the corresponding
scribe mark on the cylinder block. The rotor should
align with the position of No.1 terminal when the
distributor shaft is down in place. It may be neces-
sary to rotate the oil pump shaft with a long flat-
blade screwdriver to engage the oil pump drive
tang.
(f) Install the distributor holddown clamp and
bolt. DO NOT tighten the bolt.
(g) When the distributor is fully engaged in its
correct location, the rotor should be at the 6 o'clock
position (Fig. 14).
(h) If the distributor is not properly installed, or
if it is removed later, then the complete installa-
tion procedures must be repeated.
(13) Install the radiator or radiator/condenser, if
equipped with A/C.
(14) Fill the cooling system.
(15) Connect negative cable to battery.
Fig. 11 Timing Case Cover
Fig. 12 Oil Pump Gear Slot Alignment
Fig. 13 Distributor Rotor Pre-Positioning
Fig. 14 Correct Rotor Position
9 - 30 2.5L ENGINEJ

(a) Position the torque arm bracket to the trans-
mission. Install the bolts and tighten to 54 Nzm (40
ft. lbs.) torque.
(b) Position the support cushion onto the torque
arm bracket. Install the nuts and tighten to 54
Nzm (40 ft. lbs.) torque.
(c) Position the insulator stud assembly and up-
per nut (Fig. 11). Position the skid plate to the
studs of the support cushion and the insulator stud
(Fig. 11). Install the support cushion stud nuts and
tighten to 54 Nzm (40 ft. lbs.) torque. Install the
lower stud nut and tighten the upper and lower in-
sulator stud nuts to 41 Nzm (30 ft. lbs.) torque.
(2)AUTOMATIC TRANSMISSION:
(a) Position the torque arm bracket to the trans-
mission. Install the bolts and tighten to 54 Nzm (40
ft. lbs.) torque.
(b) Position the support cushion onto the torque
arm bracket. Install the bolts/nuts and tighten to
54 Nzm (40 ft. lbs.) torque.
(c) Position the skid plate to the studs of the sup-
port cushion and install the nuts. Tighten the sup-
port cushion stud nuts to 54 Nzm (40 ft. lbs.)
torque.
(3) Install the skid plate bolts to the sill and
tighten to 88 Nzm (65 ft. lbs.) torque.(4) Remove the transmission support.
(5) Lower the vehicle.
(6) Connect negative cable to battery.
ENGINE ASSEMBLYÐXJ VEHICLES
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND
CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste usable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(4) Remove the lower radiator hose.
(5) Remove the upper radiator hose and coolant re-
covery hose (Fig. 13).
Fig. 11 Rear MountÐYJ Vehicles (Manual
Transmission)Fig. 12 Rear MountÐYJ Vehicles (Automatic
Transmission)
9 - 54 4.0L ENGINEJ

(6) Remove upper radiator support retaining bolts
and remove radiator support.
(7) Remove the fan shroud (Fig. 13) and electric
cooling fan.
(8) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(9) Disconnect radiator fan switch wire connector.
(10)Vehicles with Air Conditioning:
(a) Discharge the A/C condenser.
(b) Remove the service valves and cap the com-
pressor ports.
(11) Remove the radiator or radiator/condenser (if
equipped with A/C).
(12) Remove the fan assembly from the idler pul-
ley.
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump (Figs. 13 and
14).
(14) Disconnect the throttle linkages (Fig. 15).
(15) Disconnect the speed control cable (if
equipped)Ð(Fig. 15).(16) Disconnect the line pressure cable (if equipped
with automatic transmission).
(17) Disconnect injection system wire harness con-
nector at the dash panel.
(18) Disconnect the distributor electrical connec-
tion and the oil pressure switch connector.
(19) 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. 15). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(20) Remove the fuel line bracket from the intake
manifold.
(21) Remove the air cleaner assembly (Fig. 16).
(22) Remove the power brake vacuum check valve
from the booster, if equipped.
(23) If equipped with power steering (Fig. 16):
(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.
(24) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(25) Raise and support the vehicle.
(26) Disconnect the wires from the starter motor
solenoid.
(27) Remove the starter motor.
(28) Disconnect the exhaust pipe from the mani-
fold.
Fig. 13 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
Fig. 14 Heater Hoses (RH Drive Vehicle)
Fig. 15 Accelerator Cable, Speed Control Cable,
Automatic Transmission Control Cable & Quick-
Connect Fuel Lines
J4.0L ENGINE 9 - 55

(28) Connect the heater hoses at the engine ther-
mostat housing and water pump.
(29) Install the fan assembly to the idler pulley.
(30) Install the radiator or radiator/condenser (if
equipped with A/C).
(31) Connect the service valves to the A/C com-
pressor ports, if equipped with A/C.
(32) Charge the air conditioner system.
(33) Connect radiator fan switch wire.
(34) Connect the radiator hoses and automatic
transmission fluid cooler pipes, if equipped.
(35) Install the fan shroud, electric cooling fan and
radiator/condenser (if equipped with A/C).
(36) Install upper radiator support.
(37) Connect the upper radiator hose and tighten
the clamp.
(38) Connect the lower radiator hose and tighten
the clamp.
(39) Fill the cooling system with reusable coolant
and/or new coolant.
(40) Align the hood to the scribe marks. Install the
hood.
(41) Connect the vacuum harness connector.
(a) Firmly push the connectors together ensuring
that the retaining tabs are engaged.
(b) Insert the vacuum connector assembly into
the retaining bracket on the intake manifold.
(42) Install the air cleaner assembly.
(43) Install the battery and connect the battery ca-
ble.
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.
(44) Start the engine, inspect for leaks and correct
the fluid levels, as necessary.
ENGINE ASSEMBLYÐYJ VEHICLES
REMOVAL
(1) Place a protective cloth over the windshield
frame. Raise the hood and rest it on the windshield
frame (Fig. 17).
(2) Disconnect the battery cables. Remove the bat-
tery.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND
CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste reusablecoolant. If the solution is clean, drain the coolant
into a clean container for reuse.
(4) Disconnect the wire connectors from the gener-
ator.
(5) Disconnect the ignition coil and distributor
wire connectors.
(6) Disconnect the oil pressure sender wire connec-
tor.
(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 retaining
tabs against the fuel tube (Fig. 18). 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 (Fig. 18).
(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 (Fig. 18).
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if equipped
(Fig. 18).
(17) Disconnect the oxygen sensor wire connector.
(18) Remove the upper radiator hose and coolant
recovery hose (Fig. 19).
(19) Disconnect lower radiator hoses at the radia-
tor.
Fig. 17 Hood on Windshield Frame
J4.0L ENGINE 9 - 57

(20) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(21) Remove the fan shroud screws.
(22) Remove the radiator attaching bolts.
(23) Remove the radiator and fan shroud (Fig. 19).
Refer to Group 7, Cooling System for the proper pro-
cedure.
(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 (Fig. 19):
(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 starter motor.
(30) Remove the flywheel housing access cover.
(31) Remove the engine support cushion-to-bracket
through bolts.
(32) Disconnect the exhaust pipe from the mani-
fold.
(33) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(34) Lower the vehicle.
(35) Attach a lifting device to the engine.
(36) Raise the engine off the front supports.
(37) Place a support stand under the flywheel
housing.
(38) Remove the remaining flywheel housing bolts.(39) Lift the engine out of the engine compartment
and install on an engine stand.
INSTALLATION
(1) 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.
(2) Insert the transmission shaft into the clutch
spline.
(3) Align the flywheel housing with the engine.
(4) Install and finger tighten the flywheel housing
lower bolts.
(5) Install the engine support cushions (if re-
moved).
(6) Remove the support stand from beneath the fly-
wheel housing.
(7) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten the nuts.
(8) Remove the engine lifting device.
(9) Raise the vehicle.
(10) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(11) Install the flywheel housing access cover.
(12) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(13) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect the coolant hoses and tighten the
clamps.
(16) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
Fig. 18 Fuel Line Quick-Connect Couplings, Air
Cleaner Assembly, Throttle & Speed Control CablesFig. 19 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Power Steering Pump
9 - 58 4.0L ENGINEJ

(17) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(18) Install the fan shroud and radiator (refer to
Group 7, Cooling System for the proper procedure).
(19) Connect the radiator hoses.
(20) Connect the throttle valve rod and retainer.
(21) Connect the throttle cable and install the rod.
(22) Install the throttle valve rod spring.
(23) Connect the speed control cable, if equipped.
(24) Connect the oxygen sensor wire connector.
(25) Install the vacuum hose and check valve on
the brake booster.
(26) Connect the coolant temperature sensor wire
connector.
(27) Connect the idle speed actuator wire connec-
tor.
(28) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(29) Install the fuel line bracket to the intake
manifold.
(30) Connect all fuel injection wire connections.
(31) Install the engine ground strap.
(32) Connect the ignition coil wire connector.
(33) Remove the coolant temperature sending unit
to permit air to escape from the block. Fill the cool-
ing system with coolant. Install the coolant tempera-
ture sending unit when the system is filled.
(34) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(35) Install the battery and connect the battery ca-
bles.
(36) Install the air cleaner bonnet to the throttle
body.
(37) Install the air cleaner.
(38) Lower the hood and secure in place.
(39) Start the engine and inspect for leaks.
(40) Stop the engine and check the fluid levels.
Add fluid, as required.
ENGINE CYLINDER HEAD COVER
A cured gasket is part of the engine cylinder head
cover.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover (Fig.
1).
(3) Disconnect the fresh air inlet hose from the en-
gine cylinder head cover (Fig. 1).
(4) Remove the engine cylinder head cover mount-
ing bolts.(5) Remove the engine cylinder head cover.
CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original grey gasket material should NOT be
removed. If sections of the gasket material are miss-
ing or are compressed, replace the engine cylinder
head cover. However, sections with minor damage
such as small cracks, cuts or chips may be repaired
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow
the gasket material to cure prior to engine cylinder
head cover installation.
INSTALLATION
(1) If a replacement cover is installed, transfer the
CCV valve grommet and oil filler cap from the orig-
inal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
(3) Connect the CCV hoses (Fig. 1).
(4) Connect negative cable to battery.
ROCKER ARMS
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the capscrews at each bridge and pivot
assembly (Fig. 2). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
Fig. 1 Engine Cylinder Head Cover
J4.0L ENGINE 9 - 59