1994 JEEP CHEROKEE belt

Wiring Diagram Name Sheet Number
Dome/Reading Lamp.........................31
Fog Lamps............................21, 22
Fog Lamp Illumination Lamp...................20
4WD Select Trac Indicator Lamp..............39, 40
Front Headlamps.........................21, 22
Full Time Indicator Lamp...................39, 40
Glove Box Lamp...........................29
Heated Rear Window Lamp....................25
Heater A/C Panel Lamp.......................25
High-Beam Indicator Lamp.....................41
Instrument Cluster Illumination Lamps.............41
Left Backup Lamp..........................55
Left Fog Lamp.............................21
Left Headlamp.............................21
Left Park/Turn Signal Lamp....................21
Left Side Marker...........................55
Left Side Marker Lamp (Front)..................21
Left Tail/Stop Lamp.........................55
Left Turn Indicator Lamp......................41
Left Turn Lamp (Amber)......................55
License Lamp.............................55
Low Washer Indicator Lamp.................39, 40
Maintenance Required Indicator Lamp...........39, 40
Malfunction Indicator Lamp..................39, 40
Park Brake Indicator Lamp.....................40
Park/Turn Signal Lamps....................21, 22
Reading Lamp.............................31
Rear Wiper/Wash Switch Lamp..................26
Right Back-up Lamp.........................56
Right Fog Lamp............................22
Right Headlamp............................22
Right Park/Turn Signal Lamp...................22
Right Side Marker..........................56
Right Side Marker Lamp (Front).................22
Right Tail/Stop Lamp........................56
Right Turn Indicator Lamp.....................41
Right Turn Lamp (Amber).....................56
Seat Belt Indicator Lamp...................39, 40
Side Marker Lamps (Front)..................21, 22
Transfer Case Lamp.........................26
Transmission Range Lamp.....................26
Underhood Lamp...........................28
Upshift Indicator Lamp.....................39, 40
Vanity Lamps.............................31
LCD Illumination Relay.........................57
Left Front Door Jamb Switch.....................50
Left Rear Door Jamb Switch.....................50
Left Speakers............................47, 48
Liftgate Switch..............................50
Low Washer Indicator Lamp...................39, 40
Main Body Connector 1........................70
Maintenance Required Indicator Lamp............39, 40
Map Sensor................................11
Modules
Chime Module.............................43
Fuel Pump Module..........................54
Intermittent Wiper Module.....................33
Powertrain Control Module . .7, 9, 10, 11, 12, 13, 14, 45, 53Wiring Diagram Name Sheet Number
Transmission Control Module.................17, 18
Motors
A/C Heater Blower Motor......................46
Engine Starter Motor.........................6
Front Wiper Motor..........................34
Heater Blower Motor.........................44
Idle Air Control Motor........................14
Radiator Fan Motor..........................7
Rear Wiper Motor..........................36
Oil Pressure and Temperature System...............15
Coolant Temperature Switch....................15
Oil Pressure Switch.........................15
Park Brake Indicator Lamp......................40
Park Brake Switch............................42
Power Distribution Center........................1
Power Distribution Center Application Chart............4
Power Distribution Center Identification...............3
Power Mirror Connector........................61
Power Mirror Switch Assembly...................51
Power Mirrors............................51, 52
Heater Element............................52
Left Power Mirror..........................52
Right Power Mirror.........................52
Powertrain Control Module . . .7, 9, 10, 11, 12, 13, 14, 45, 53
Powertrain Control Module Connector...............73
Pumps
Front Washer.............................34
Rear Washer..............................35
Fuel...................................54
Radiator Fan Motor............................7
Radio.................................47, 48
Antenna Mast.............................47
Left Instrument Panel Speaker..................47
Left Liftgate Speaker.........................48
Radio..................................47
Right Instrument Panel Speaker.................48
Right Liftgate Speaker........................48
Rear Lighting............................55, 56
Left Back-Up Lamp..........................55
Left Side Marker...........................55
Left Tail/Stop Lamp.........................55
Left Turn Lamp (Amber)......................55
License Lamp.............................55
Right Back-Up Lamp.........................56
Right Side Marker..........................56
Right Tail/Stop Lamp........................56
Right Turn Lamp (Amber).....................56
Rear Wiper/Washer.........................35, 36
Rear Washer Pump.........................35
Rear Wiper Motor..........................36
Rear Wiper/Washer Switch.....................35
Reading Lamps..............................31
Relays
A/C Compressor Clutch Relay.................3,45
Automatic Shut Down Relay...................3,9
Engine Starter Relay........................3,6
Fan Control Relay.........................3,7
Fog Lamp Relay...........................21
JWIRING DIAGRAMS 8W - 273

Wiring Diagram Name Sheet Number
Fuel Pump Relay..........................3,9
Heated Rear Window Relay....................60
Horn Relay...............................27
LCD Illumination Relay.......................57
Right Front Door Jamb Switch....................49
Right Rear Door Jamb Switch....................49
Right Speaker...............................48
Seat Belt Switch.............................43
Seat Belt Indicator Lamp.....................39, 40
Sensors
Camshaft Position Sensor.....................12
Crankshaft Position Sensor.....................12
Engine Coolant Temperature Sensor...............11
Fuel Gauge Sensor..........................54
Heated Oxygen Sensor.......................13
Intake Air Temperature Sensor..................11
Map Sensor..............................11
Throttle Position Sensor......................11
Vehicle Speed Sensor........................16
Speakers, Radio...........................47, 48
Splices
Splice A3..............................1,19
Splice A11................................5
Splice A14................................9
Splice A21................................9
Splice A21-1............................8,43
Splice A48.............................2,33
Splice A142..............................14
Splice A142-1.............................14
Splice A142-2.........................5,10,14
Splice C7................................46
Splice C15...............................52
Splice C15-1..............................52
Splice C43............................44, 46
Splice C90...............................45
Splice E2................................25
Splice F12...............................10
Splice F85.............................47, 58
Splice G7.............................12, 16
Splice K4................................11
Splice K4-1...............................11
Splice K6................................11
Splice K7................................12
Splice K22...............................11
Splice K29................................9
Splice L3................................21
Splice L90...............................55
Splice L90-1..............................22
Splice L90-2..............................56
Splice L90-3..............................55
Splice M1................................31
Splice M1-1..............................29
Splice M2................................30
Splice M2-1..............................29
Splice M2-2..............................30
Splice P79...............................51
Splice V32...............................53
Splice Z1-1...............................59Wiring Diagram Name Sheet Number
Splice Z1-2...............................20
Splice Z1-3...............................32
Splice Z1-4...............................28
Splice Z1-5............................59, 60
Splice Z1-6...............................55
Splice Z1-7...............................56
Splice Z1-10..............................22
Splice Z1-13..............................51
Splice Z1-14...............................7
Splice Z1-15..............................59
Splice Z1-16..............................16
Splice Z11...............................10
Splice Z12-1..............................13
Splice 117...............................21
Starter System...............................6
Battery..................................6
Engine Starter Motor.........................6
Engine Starter Relay..........................6
Steering Column Connector 11 Way................67
Stop Lamp Switch............................24
Stop/Turn and Hazard System..................23, 24
Hazard Flasher.............................24
Hazard Switch.............................24
Stop Lamp Switch..........................24
Turn and Hazard Flasher Switch.................24
Turn Signal Flasher..........................23
Switches
A/C Low Pressure Switch.....................45
A/C Mode Selector Switch.....................46
Back-Up Lamp Switch........................16
Blower Switch..........................44, 46
Brake Warning Switch........................42
Engine Coolant Temperature Switch...............15
Engine Oil Pressure Switch....................15
Fog Lamp Switch...........................20
Front Axle Switch...........................16
Hazard Switch.............................24
Headlamp Dimmer Switch.....................19
Headlamp Switch.........................1,19
Heated Rear Window Switch....................60
Heat Mode Select Switch......................44
Horn Switch..............................27
Ignition Key Warning Switch....................43
Ignition Switch.............................8
Left Front Door Jamb Switch...................50
Left Rear Door Jamb Switch...................50
Liftgate Switch............................50
Oil Pressure Switch.........................15
Park Brake Switch..........................42
Park Switch (Wiper).........................34
Power Mirror Switch.........................51
Rear Wiper/Washer Switch.....................35
Reed Switch..............................18
Right Front Door Jamb Switch..................49
Right Rear Door Jamb Switch..................49
Seat Belt Switch...........................43
Stop Lamp Switch..........................24
Transmission Range Switch....................17
8W - 274 WIRING DIAGRAMSJ

can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended during assembly to pre-
vent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label
found on the engine compartment hood.
(1) Test battery specific gravity. Add water, if nec-
essary. Clean and tighten battery connections.
(2) Test cranking amperage draw (refer to Group
8B, Battery/Starter Service for the proper proce-
dures).
(3) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
CAUTION: DO NOT overspeed the engine.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators - fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maxi-
mum pressure is reached on gauge. Record this
pressure as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.
(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 4a through 4h.
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engineproblems. An engine should NOT be disassem-
bled to determine the cause of low compression
unless some malfunction is present.
(5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(6) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
(7) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(8) Set ignition timing to specifications (refer to
Specification Label on engine compartment hood).
(9) Perform a combustion analysis.
(10) Test fuel pump for pressure and vacuum (refer
to Group 14, Fuel System for the proper specifica-
tions).
(11) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(12) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(13) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(14) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(15) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
9 - 2 ENGINESJ

ENGINE DIAGNOSIS
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine tune-ups.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or me-
chanical (e.g., a strange noise).
Refer to the Service DiagnosisÐPerformance chart
and the Service DiagnosisÐMechanical chart for pos-
sible causes and corrections of malfunctions. Refer to
Group 14, Fuel System for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts. In-
formation concerning additional tests and diagnosis
is provided within the following diagnosis:
²Cylinder Compression Pressure Test.
²Cylinder Combustion Pressure Leakage Test.
²Engine Cylinder Head Gasket Failure Diagnosis.
²Intake Manifold Leakage Diagnosis.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
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 THE FAN.
DO NOT WEAR LOOSE CLOTHING.
METHOD 1
(1) Start the engine.
(2) Open the acetylene valve of an oxyacetylene
torch. DO NOT ignite.
(3) Pass the torch tip over the exposed gasket area
(EDGE) between the manifold and the engine cylin-
der head.
(4) If the engine speed increases, the manifold has
an air leak.
METHOD 2
(1) Start the engine.
(2) Apply engine oil to the exposed gasket area
(EDGE) between the manifold and the engine cylin-
der head.
(3) If oil is forced into the manifold and if smoke is
visible from the exhaust tailpipe, the manifold has
an air leak.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the 3rd
revolution. Continue the test for the remaining cyl-
inders.
Refer to Engine Specifications for the correct en-
gine compression pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A leaking engine cylinder head gasket usually re-
sults in loss of power, loss of coolant and engine mis-
firing.
An engine cylinder head gasket leak can be located
between adjacent cylinders or between a cylinder and
the adjacent water jacket.
²An engine cylinder head gasket leaking between
adjacent cylinders is indicated by a loss of power
and/or engine misfire.
²An engine cylinder head gasket leaking between a
cylinder and an adjacent water jacket is indicated by
coolant foaming or overheating and loss of coolant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders; follow the proce-
dures outlined in Cylinder Compression Pressure
Test. An engine cylinder head gasket leaking be-
tween adjacent cylinders will result in approximately
a 50-70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE
TEST
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 THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radiator cap.
Start the engine and allow it to warm up until the
engine thermostat opens.
If a large combustion/compression pressure leak ex-
ists, bubbles will be visible in the coolant.
If bubbles are not visible, install a radiator pres-
sure tester and pressurize the coolant system.
JENGINES 9 - 5

(14) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(15) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(16) Install the oil filter.
(17) Lower the vehicle.
(18) Connect the coolant hoses and tighten the
clamps.
(19) 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.
(20) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(21) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(22) Install the fan shroud and radiator.
(23) Connect the radiator hoses.
(24) Connect the heater hoses.
(25) Connect the throttle valve rod and retainer.
(26) Connect the throttle cable and install the rod.
(27) Install the throttle valve rod spring.
(28) Connect the speed control cable, if equipped.
(29) Connect the oxygen sensor wire connector.
(30) Install the vacuum hose and check valve on
the brake booster.
(31) Connect the coolant temperature sensor wire
connector.
(32) Connect the idle speed actuator wire connec-
tor.
(33) 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.
(34) Install the fuel line bracket to the intake
manifold.
(35) Connect all fuel injection wire connections.
(36) Install the engine ground strap.
(37) Connect the ignition coil wire connector.
(38) 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.
(39) Install the battery and connect the battery ca-
bles.
(40) Install the air cleaner bonnet to the throttle
body.
(41) Install the air cleaner.
(42) Lower the hood and secure in place.
(43) Start the engine and inspect for leaks.
(44) 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 the oil filler cap from the origi-
nal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
Fig. 1 Engine Cylinder Head Cover
9 - 18 2.5L ENGINEJ

(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.
(3) Check for rocker arm bridges which are caus-
ing misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessivelyworn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensure
that the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their originally position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
Fig. 2 Rocker Arm Assembly
J2.5L ENGINE 9 - 19

(5) Place the engine cylinder head over the dowels.
CAUTION: Engine cylinder head bolts should be re-
used only once. Replace the head bolts if they were
used before or if they have a paint dab on the top
of the bolt.
(6) Coat the threads of bolt No.7, only, with Loctite
PST sealant or equivalent.
(7) Install all head bolts, except No.8 and No.10.
(8) Remove the dowels.
(9) Install No.8 and No.10 head bolts.
(10) Tighten the engine cylinder head bolts in se-
quence according to the following procedure (Fig. 6):
(a) Tighten all bolts in sequence (1 through 10)
to 30 Nzm (22 ft. lbs.) torque.
(b) Tighten all bolts in sequence (1 through 10)
to 61 Nzm (45 ft. lbs.) torque.
(c) Check all bolts to verify they are set to 61
Nzm (45 ft. lbs.) torque.
(d) Tighten bolts (in sequence):
²Bolts 1 through 6 to 149 Nzm (110 ft. lbs.) torque.
²Bolt 7 to 136 Nzm (100 ft. lbs.) torque.
²Bolts 8 through 10 to 149 Nzm (110 ft. lbs.) torque.
CAUTION: During the final tightening sequence,
bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(e) Check all bolts in sequence to verify the cor-
rect torque.
(f) If not already done, clean and mark each bolt
with a dab of paint after tightening. Should you
encounter bolts which were painted in an earlier
service operation, replace them.
(11) Install the ignition coil and bracket assembly.
(12) Connect the temperature sending unit wire
connector.
(13) Install the spark plugs and tighten to 37 Nzm
(27 ft. lbs.) torque. Connect the ignition wires.(14) Install the intake and exhaust manifolds (re-
fer to Group 11, Exhaust System and Intake Mani-
fold for the proper procedures).
(15) Install the fuel lines and the vacuum advance
hose.
(16) If equipped, attach the power steering pump
and bracket.
(17) Install the push rods, rocker arms, pivots and
bridges in the order they were removed.
(18) Install the engine cylinder head cover.
(19) Attach the air conditioning compressor mount-
ing bracket to the engine cylinder head and block.
Tighten the bolts to 40 Nzm (30 ft. lbs.) torque.
(20) Attach the air conditioning compressor to the
bracket. Tighten the bolts to 27 Nzm (20 ft. lbs.)
torque.
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(21) Install the serpentine drive belt and correctly
tension the belt (refer to Group 7, Cooling System for
the proper procedure).
(22) Install the air cleaner and ducting.
(23) Install the engine cylinder head cover.
(24) Connect the hoses to the thermostat housing
and fill the cooling system to the specified level (re-
fer to Group 7, Cooling Systems for the proper proce-
dure).
(25) The automatic transmission throttle linkage
and cable must be adjusted after completing the en-
gine cylinder head installation (refer to Group 21,
Transmissions for the proper procedures).
(26) Install the temperature sending unit and con-
nect the wire connector.
(27) Connect the fuel pipe and vacuum advance
hose.
(28) Connect negative cable to battery.
(29) Connect the upper radiator hose and heater
hose at the thermostat housing.
(30) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(31) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
VALVE SPRINGS AND OIL SEALS
This procedure can be done with the engine cylin-
der head installed on the block.
Fig. 6 Engine cylinder head Bolt Tightening
Sequence
J2.5L ENGINE 9 - 21

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