1995 JEEP CHEROKEE steering

Fig. 5 Battery and Generator Wiring
Fig. 6 Steering Column Wiring Connectors
J8W-90 CONNECTOR LOCATIONSÐXJ-RHD 8W - 90 - 7

(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 - 18 2.5L ENGINEJ

(a) Disconnect the power steering hoses from the
fittings at the steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign material from entering the
system.
(21) Disconnect the coolant hoses from the rear of
the intake manifold.
(22) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(23) Raise the vehicle.
(24) Remove the oil filter.
(25) Remove the starter motor.
(26) Disconnect the exhaust pipe from the exhaust
manifold.
(27) Remove the flywheel and converter housing
access cover.
(28) If equipped with an automatic transmission,
mark the converter and drive plate location in refer-
ence to each other and remove the converter-to-drive
plate bolts.(29) Remove the upper flywheel and converter
housing bolts and loosen the bottom bolts.
(30) Remove the engine support cushion-to-engine
compartment bracket bolts.
(31) Remove the engine shock damper bracket
from the sill.
(32) Lower the vehicle.
(33) Attach a lifting device to the engine.
(34) Raise the engine slightly off the front sup-
ports.
(35) Place a support stand under the converter or
flywheel housing.
(36) Remove the remaining bottom converter or
flywheel housing bolts.
(37) Lift the engine out of the engine compartment
and install on an engine stand.
(38) Install the oil filter to keep foreign material
out of the engine.
INSTALLATION
(1) Remove the oil filter.
(2) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(3) If equipped with a manual transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.
(c) Install and tighten the flywheel housing lower
bolts finger tight.
(4) If equipped with an automatic transmission:
Fig. 16 Heater Hoses (LH Drive Vehicles), Throttle
Linkage & Quick-Connect Fuel Lines
Fig. 17 Heater Hoses (RH Drive Vehicle)
Fig. 18 Air Cleaner and Power Steering Pump
J2.5L ENGINE 9 - 19

(a) Align the transmission torque converter hous-
ing 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 and converter
housing 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 and con-
denser (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 compres-
sor 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 - 20 2.5L ENGINEJ

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

(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 man-
ifold.
(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 dark grey gasket material should NOT
be removed. If sections of the gasket material are
missing or are compressed, replace the engine cylin-
der 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 - 22 2.5L ENGINEJ

LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 14).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Universal Leak-
Down Tester .
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di-
ameter ball bearing on the plunger cap of the tappet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. DO NOT tighten
the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal po-
sition.
(6) Adjust the nose of the ram to align the pointer
with the SET mark on the scale of the tester and
tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the
base of the tester clockwise one revolution every 2
seconds.
(9) Observe the leak-down time interval from the
instant the pointer aligns with the START mark on
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-
110 seconds to leak-down. Discard tappets with leak-
down time interval not within this specification.
INSTALLATION
It is not necessary to charge the tappets with en-
gine oil. They will charge themselves within a very
short period of engine operation.(1) Dip each tappet in Mopar Engine Oil Supple-
ment, or equivalent.
(2) Use Hydraulic Valve Tappet Removal/Installa-
tion Tool C-4129-A to install each tappet in the same
bore from where it was originally removed.
(3) Install the push rods in their original locations.
(4) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(5) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(6) Pour the remaining Mopar Engine Oil Supple-
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
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.
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:
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside.
(b) Remove the air conditioner compressor
bracket bolts from the engine cylinder head.
(c) Loosen the through bolt at the bottom of the
bracket.
Fig. 14 Leak-Down Tester
J2.5L ENGINE 9 - 25

(9) If equipped, disconnect the power steering
pump bracket. Set the pump and bracket aside. DO
NOT disconnect the hoses.
(10) Remove the fuel lines and vacuum advance
hose.
(11) Remove the intake and engine exhaust mani-
folds from the engine cylinder head (refer to Group
11, Exhaust System and Intake Manifold for the
proper procedures).
(12) Disconnect the ignition wires and remove the
spark plugs.
(13) Disconnect the temperature sending unit wire
connector.
(14) Remove the ignition coil and bracket assem-
bly.
(15) Remove the engine cylinder head bolts.
(16) Remove the engine cylinder head and gasket
(Fig. 3).
(17) If this was the first time the bolts were re-
moved, put a paint dab on the top of the bolt. If the
bolts have a paint dab on the top of the bolt or it
isn't known if they were used before, discard the
bolts.
(18) Stuff clean lint free shop towels into the cylin-
der bores.
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and ex-
haust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
INSTALLATION
The engine cylinder head gasket is a composition
gasket. The gasket is to be installed DRY.DO NOT
use a gasket sealing compound on the gasket.
If the engine cylinder head is to be replaced and
the original valves used, measure the valve stem di-
ameter. Only standard size valves can be used with a
service replacement engine cylinder head unless the
replacement head valve stem guide bores are reamed
to accommodate oversize valve stems. Remove all
carbon buildup and reface the valves.
(1) Fabricate two engine cylinder head alignment
dowels from used head bolts (Fig. 4). Use the longest
head bolt. Cut the head of the bolt off below the hex
head. Then cut a slot in the top of the dowel to allow
easier removal with a screwdriver.
(2) Install one dowel in bolt hole No.10 and the
other dowel in bolt hole No.8 (Fig. 5).
(3) Remove the shop towels from the cylinder
bores. Coat the bores with clean engine oil.
(4) Place the engine cylinder head gasket (with the
numbers facing up) over the dowels.
(5) Place the engine cylinder head over the dowels.
Fig. 3 Engine Cylinder Head Assembly
Fig. 4 Fabricate Alignment Dowels
Fig. 5 Alignment Dowel Locations
9 - 26 2.5L ENGINEJ