1994 JEEP CHEROKEE fuel pressure

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

CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage, or equivalent. The
following is the recommended procedures for the use
of Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing cap shell (Fig. 2). Position the
Plastigage approximately 6.35 mm (1/4 inch) off cen-
ter and away from the oil holes. In addition, suspect
areas can be checked by placing the Plastigage in the
suspect area.
(3) The crankshaft must be turned until the con-
necting rod to be checked starts moving toward the
top of the engine. Only then should the rod cap with
Plastigage in place be assembled. Tighten the rod
cap nut to 45 Nzm (33 ft. lbs.) torque.DO NOT ro-
tate the crankshaft or the Plastigage may be
smeared, giving inaccurate results.
(4) Remove the bearing cap and compare the width
of the flattened Plastigage with the scale provided on
the package (Fig. 3). Plastigage generally comes in 2
scales (one scale is in inches and the other is a met-
ric scale). Locate the band closest to the same width.
This band shows the amount of clearance. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken
(refer to Engine Specifications).
(5) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
is usually the most appropriate for checking engine
bearing clearances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole.
This brings the hole back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A service replacement engine assembly (short
block) may be installed whenever the original cylin-
der block is defective or damaged beyond repair. It
consists of the cylinder block, crankshaft, piston and
rod assemblies. If needed, the camshaft must be pro-
cured separately and installed before the engine is
installed in the vehicle.
A short block is identified with the letter ``S'' stamped
on the same machined surface where the build date
code is stamped for complete engine assemblies.
Installation includes the transfer of components
from the defective or damaged original engine. Fol-
low the appropriate procedures for cleaning, inspec-
tion and torque tightening.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Disconnect the negative cable from the battery.
(3) Inspect air cleaner, induction system and in-
take manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure in
the cylinder head. Remove the plugs from the engine.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 37 Nzm (27 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
Nzm (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil (refer to Group 0, Lubrica-
tion and Maintenance).
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
Fig. 3 Clearance Measurement
9 - 4 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

(2) Install the upper inner retainer and bushing on
the top of the damper.
(3) Position the upper damper bracket over the
damper and install the stud nut and bolts.
(4) Tighten the stud nut to 23 Nzm (17 ft. lbs.)
torque. Tighten the bracket bolts to 61 Nzm (45 ft.
lbs.) torque.
(5) Install the bushing, upper outer retainer and
damper nut.
(6) Install the bushing, lower outer retainer and
damper nut.
(7) Tighten the upper and lower damper nuts.
(8) 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. 15).
(6) Remove the fan shroud (Fig. 15).
(7) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(8) Remove the radiator/condenser (if equipped
with air conditioning).
(9) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and wa-
ter pump in alignment when crankshaft is rotated.
(10) Disconnect the heater hoses (Figs. 16 and 17).
(11) Disconnect the throttle linkages (Fig. 16),
speed control cable (if equipped) and throttle valve
rod.
(12) Disconnect the oxygen sensor wire connector.
(13) Disconnect the wires from the starter motor
solenoid.
(14) Disconnect all fuel injection harness connec-
tions.
(15) 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. 16). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove the fuel line bracket from the intake
manifold.
(17) Remove the air cleaner assembly (Fig. 18).
(18) If equipped with air conditioning, remove the
service valves and cap the compressor ports.
(19) Remove the power brake vacuum check valve
from the booster, if equipped.
(20) If equipped with power steering (Fig. 18):
Fig. 14 Engine Damper
Fig. 15 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
9 - 14 2.5L ENGINEJ

(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger-tight.
(5) Install the engine support cushions (if re-
moved).
(6) Lower the engine and engine support cushions
onto the engine compartment brackets.
(7) Remove the engine lifting device.
(8) Raise the vehicle.
(9) If equipped with an automatic transmission:
(a) Install the converter-to-drive plate bolts. En-
sure the installation reference marks are aligned.
Tighten the bolts to 54 Nzm (40 ft. lbs.) torque.
(b) Install the converter-housing access cover.
(c) Install the exhaust pipe support.
(10) Install the remaining converter or flywheel
housing bolts.
(11) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(12) Tighten the engine support cushing through-
bolt nuts.
(13) Install the remaining flywheel/converter hous-
ing bolts. Tighten the bolts to 38 Nzm (28 ft. lbs.)
torque.
(14) Connect the exhaust pipe to the manifold.
(15) Install the oil filter.
(16) Lower the vehicle.
(17) Connect the coolant hoses and tighten the
clamps.
(18) 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.
(19) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(20) Install the fan shroud and radiator/condenser
(if equipped with air conditioning).
(21) Connect the radiator hoses.
(22) Connect the automatic transmission fluid
cooler pipes, if equipped.
(23) Connect the oxygen sensor wire connector.
(24) Connect the throttle valve rod and retainer.
Connect the throttle cable and install the rod. Install
the throttle valve rod spring.
(25) Connect the speed control cable, if equipped.
(26) Connect the fuel supply and return lines to
the throttle body.
(27) Connect all the vacuum hoses and wire con-
nectors.
(28) Connect the service valves to the A/C com-
pressor ports, if equipped with air conditioning.(29) Fill the power steering reservoir.
(30) Connect the battery cables.
(31) Install the hood.
(32) Install the air cleaner.
(33) Start the engine and inspect for leaks.
(34) Fill the cooling system.
(35) Stop the engine and check the fluid levels.
Add fluid, as required.
ENGINE ASSEMBLYÐYJ VEHICLES
REMOVAL
(1) Place a protective cloth over the windshield
frame. Raise the hood and rest it on the windshield
frame (Fig. 19).
(2) Disconnect the battery cable clamps and re-
move the battery.
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) 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.
Fig. 19 Hood on Windshield Frame
9 - 16 2.5L 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

(29) Disconnect the engine speed sensor wire con-
nection.
(30) Remove the exhaust pipe support.
(31) Remove the flywheel/converter housing access
cover.
(32)Vehicles with Automatic Transmission:
(a) Mark the converter and drive plate location.
(b) Remove the converter-to-drive plate bolts.
(33) Remove the upper flywheel/converter housing
bolts and loosen the bottom bolts.
(34) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(35) Lower the vehicle.
(36) Attach a lifting device to the engine.
(37) Raise the engine off the front supports.
(38) Place a support or floor jack under the con-
verter (or flywheel) housing.
(39) Remove the remaining converter (or flywheel)
housing bolts.
(40) Lift the engine out of the engine compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the en-
gine mount cushions from the engine mount bracket
as an aide in alignment of the engine to the trans-
mission.
(2)Vehicles with 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.(3)Vehicles with Automatic Transmission:
(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger tight.
(4) Install the engine mount cushions (if removed).
(5) Lower the engine and engine mount cushions
onto the engine compartment brackets. Install the
bolts and finger tighten the nuts.
(6) Remove the engine lifting device.
(7) Raise and support the vehicle.
(8) Install the remaining flywheel/converter hous-
ing bolts. Tighten all bolts to 38 Nzm (28 ft. lbs.)
torque.
(9)Vehicles with Automatic Transmission:
(a) Install the converter-to-drive plate bolts.
(b) Ensure the installation reference marks are
aligned.
(10) Install the flywheel/converter housing access
cover.
(11) Install the exhaust pipe support and tighten
the screw.
(12) Tighten the engine mount-to-bracket bolts.
(13) Connect the engine speed sensor wire connec-
tions and tighten the screws.
(14) Connect the exhaust pipe to the manifold.
(15) Install the starter motor and connect the ca-
ble.
(16) Connect the wires to the starter motor sole-
noid.
(17) Lower the vehicle.
(18) Connect all the vacuum hoses and wire con-
nectors identified during engine removal.
(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) Install the power brake vacuum check valve
to the booster, if equipped.
(21) 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.
(22) Install the fuel line bracket to the intake
manifold.
(23) Connect the distributor electrical connector
and oil pressure switch connector.
(24) Connect the injection system wire harness
connector on the dash panel.
(25) Connect the line pressure cable (if equipped
with automatic transmission).
(26) Connect the speed control cable, if equipped.
(27) Connect the throttle cable linkages.
Fig. 16 Air Cleaner Assembly & Power Steering
Pump
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