1995 JEEP CHEROKEE light

(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

(3) Connect the CCV hoses (Fig. 1).
(4) Connect negative cable to battery.
VALVE COMPONENT REPLACEÐCYLINDER HEAD
NOT REMOVED
ROCKER ARMS AND PUSH RODS
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 causing
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 excessively
worn 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 original 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.
VALVE SPRINGS AND OIL SEALS
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer and
a set of conical valve locks. The locks can be removed
only by compressing the valve spring.
(1) Remove the engine cylinder head cover.
(2) Remove capscrews, bridge and pivot assemblies
and rocker arms for access to each valve spring to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same order
and position as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed.
(6) Install a 14 mm (1/2 inch) (thread size) air hose
adaptor in the spark plug hole.
(7) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats. For vehicles equipped with an air
conditioner, use a flexible air adaptor when servicing
the No.1 cylinder.
(8) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Fig. 2 Rocker Arm Assembly
J2.5L ENGINE 9 - 23

Compressor Tool MD-998772A to compress the spring
and remove the locks (Fig. 7).
(9) Remove valve spring and retainer (Fig. 7).
(10) Remove valve stem oil seals (Fig. 7). Note the
valve seals are different for intake and exhaust
valves. The top of each seal is marked either INT (In-
take) or EXH (Exhaust). DO NOT mix the seals.
INSPECTION
Inspect the valve stems, especially the grooves. An
Arkansas smooth stone should be used to remove
nicks and high spots.
INSTALLATION
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Lightly push the valve seal over the valve stem
and valve guide boss. Be sure the seal is completely
seated on the valve guide boss.
(2) Install valve spring and retainer.
(3) Compress the valve spring with Valve Spring
Compressor Tool MD-998772A and insert the valve
locks. Release the spring tension and remove the
tool. Tap the spring from side-to-side to ensure that
the spring is seated properly on the engine cylinder
head.
(4) Disconnect the air hose. Remove the adaptor
from the spark plug hole and install the spark plug.
(5) Repeat the procedures for each remaining valve
spring to be removed.
(6) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.(7) Install the rocker arms, pivots and bridge at
their original location.
(8) Tighten the bridge capscrews alternately, one
at a time, to avoid damaging the bridge. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(9) Install the engine cylinder head cover.
HYDRAULIC TAPPETS
Retain all the components in the same order as re-
moved.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the bridge and pivot assemblies and
rocker arms by removing the capscrews at each
bridge. Alternately loosen each capscrew, one turn at
a time, to avoid damaging the bridges.
(3) Remove the push rods.
(4) Remove the tappets through the push rod open-
ings in the cylinder head with Hydraulic Valve Tap-
pet Removal/Installation Tool C-4129-A (Fig. 13).
CLEANING
Clean each tappet assembly in cleaning solvent to
remove all varnish, gum and sludge deposits.
INSPECTION
Inspect for indications of scuffing on the side and
base of each tappet body.
Inspect each tappet base for concave wear with a
straightedge positioned across the base. If the base is
concave, the corresponding lobe on the camshaft is
also worn. Replace the camshaft and defective tap-
pets.
Fig. 7 Valve and Valve Components
Fig. 13 Hydraulic Valve Tappet Removal/Installation
Tool C-4129-A
9 - 24 2.5L ENGINEJ

PREFERRED METHOD:
(1) Remove the valve from the head.
(2) Clean the valve stem guide bore with solvent
and a bristle brush.
(3) Insert a telescoping gauge into the valve stem
guide bore approximately 9.525 mm (.375 inch) from
the valve spring side of the head (Fig. 10).
(4) Remove and measure telescoping gauge with a
micrometer.
(5) Repeat the measurement with contacts length-
wise to engine cylinder head.
(6) Compare the crosswise to lengthwise measure-
ments to determine out-of-roundness. If the measure-
ments differ by more than 0.0635 mm (0.0025 in.),
ream the guide bore to accommodate an oversize
valve stem.
(7) Compare the measured valve guide bore diam-
eter with specifications (7.95-7.97 mm or 0.313-0.314
inch). If the measurement differs from specification
by more than 0.076 mm (0.003 inch), ream the guide
bore to accommodate an oversize valve stem.
ALTERNATIVE METHOD:
(1) Use a dial indicator to measure the lateral
movement of the valve stem (stem-to-guide clear-
ance). This must be done with the valve installed in
its guide and just off the valve seat (Fig. 11).
(2) Correct clearance is 0.025-0.0762 mm (0.001-
0.003 inch). If indicated movement exceeds the spec-
ification ream the valve guide to accommodate an
oversize valve stem.
Valve seats must be ground after reaming the
valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a Universal Valve Spring Tester and a torque
wrench to test each valve spring for the specified ten-
sion value (Fig. 12).
Replace valve springs that are not within specifica-
tions.
INSTALLATION
(1) Thoroughly clean the valve stems and the valve
guide bores.
(2) Lightly lubricate the stem.
(3) Install the valve in the original valve guide
bore.
(4) Install the replacement valve stem oil seals on
the valve stems. If the 0.381 mm (0.015 inch) over-
size valve stems are used, oversize oil seals are re-
quired.
(5) Position the valve spring and retainer on the
engine cylinder head and compress the valve spring
with Valve Spring Compressor Tool MD-998772A.
(6) Install the valve locks and release the tool.
(7) Tap the valve spring from side to side with a
hammer to ensure that the spring is properly seated
Fig. 10 Measurement of Valve Guide Bore Diameter
Fig. 11 Measurement of Lateral Movement Of Valve
Stem
Fig. 12 Valve Spring Tester
J2.5L ENGINE 9 - 29

at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks.
(8) Install the engine cylinder head.
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 7697 to re-
move 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. 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.
(8) Remove the tools. Apply a light film of engine
Fig. 1 Vibration Damper Removal Tool 7697
Fig. 3 Timing Case Cover Oil Seal Installation
9 - 30 2.5L ENGINEJ

oil on the vibration damper hub contact surface of
the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(10) Install the serpentine belt and tighten to the
specified tension (refer to Group 7, Cooling Systems
for the proper specifications and procedures).
(11) Install the radiator shroud.
(12) Connect negative cable to battery.
TIMING CASE COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Fig. 4).
(3) Remove the fan and hub assembly and remove
the fan shroud.
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and
generator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 4).
CLEANING
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
INSTALLATION
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward
the inside of the cover. Support the cover at the sealarea while installing the seal. Force it into position
with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
(3) Position the timing case cover on the oil pan
gasket and the cylinder block.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 5).
(5) Install the timing case cover-to-cylinder block
and the oil pan-to-timing case cover bolts.
(6) Tighten the 1/4 inch cover-to-block bolts to 7
Nzm (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 Nzm (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 14 Nzm
(120 in. lbs.) torque. Tighten the oil pan-to-cover 5/16
inch bolts to 18 Nzm (156 in. lbs.) torque.
(7) Remove the cover alignment tool.
(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key inserted in the keyway in the crank-
shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 Nzm (80 ft. lbs.)
torque.
(10) Install the A/C compressor (if equipped) and
generator bracket assembly.
(11) Install the engine fan and hub assembly and
shroud.
(12) Install the serpentine drive belt and tighten to
obtain the specified tension.
(13) Connect negative cable to battery.
TIMING CHAIN AND SPROCKETS
The timing chain tensioner reduces noise and pro-
longs timing chain life. In addition, it compensates
for slack in a worn or stretched chain and maintains
the correct valve timing.
Fig. 4 Timing Case Cover Components
Fig. 5 Timing Case Cover Alignment and Seal
Installation Tool 6139
J2.5L ENGINE 9 - 31

SIDE CLEARANCE MEASUREMENT
Slide snug-fitting feeler gauge between the connect-
ing rod and crankshaft journal flange. Refer to En-
gine Specifications for the proper clearance. Replace
the connecting rod if the side clearance is not within
specification.
PISTON FITTING
BORE GAUGE METHOD
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, Special Tool 6879 or equivalent, ca-
pable of reading in .00019INCREMENTS with gauge
ring Special Tool 6884 is required. If a bore gauge is
not available, do not use an inside micrometer.
(2) Set the bore gauge to the gauge ring and zero
gauge.
(3) Remove gauge from ring and check cylinder as
shown in (Fig. 8) bore and record reading.
(4) Measure the inside diameter of the cylinder
bore at a point 58.725 mm (2-5/16 inches) below top
of bore. Start perpendicular (across or at 90 degrees)
to the axis of the crankshaft at point B and then take
an additional bore reading 90 degrees to that at point A.
(5) Recheck bore gauge in gauge ring, bore gauge
should read zero. If gauge does not read zero, reset
gauge and start over with procedure.
The coated pistons will be serviced with the piston
pin and connecting rod pre-assembled.The coated
piston connecting rod assembly can be used to
service previous built engines and MUST be re-
placed as complete sets.Tin coated pistons should
not be used as replacements for the new coated pistons.
The coating material is applied to the piston after
the final piston machining process. Measuring the
outside diameter of a coated piston will not provide
accurate results. Therefore, measuring the inside di-
ameter of the cylinder bore with a dial Bore Gauge is
MANDATORY. To correctly select the proper size
piston, a cylinder bore gauge capable of reading in.00019increments is required.
Piston installation into the cylinder bore requires
slightly more pressure than that required for non-
coated pistons. The bonded coating on the piston will
give the appearance of a line-to-line fit with the cyl-
inder bore.
PISTON PIN
Piston pins are press-fitted into the connecting rods
and require no locking device. The piston, piston pin
and connecting rod are replaced as an assembly.
PISTON RING FITTING
(1) Carefully clean the carbon from all ring
grooves. Oil drain openings in the oil ring groove and
pin boss must be clear. DO NOT remove metal from
the grooves or lands. This will change ring-to-groove
clearances and will damage the ring-to-land seating.
(2) Be sure the piston ring grooves are free of nicks
and burrs.
(3) Measure the ring side clearance with a feeler
gauge fitted snugly between the ring land and ring
(Fig. 10). Rotate the ring in the groove. It must move
freely around circumference of the groove.
(4) Place ring in the cylinder bore and push down
with inverted piston to position near lower end of the
ring travel. Measure ring gap with a feeler gauge fit-
ting snugly between ring ends (Fig. 12). The correct
compression ring end gap is 0.25-0.51 mm (0.010-
0.020 inch). The correct oil control ring end gap is
0.381-1.397 mm (0.015-0.055 inch).
Fig. 8 Bore Gauge
Fig. 9 Piston Size Chart
Fig. 10 Piston Dimensions
9 - 42 2.5L ENGINEJ

(9) The top compression ring (the scraping edge is
gray in color) has a chamfer on the TOP of the inside
edge (Fig. 16). This ring may also have 1 dot located
on the top surface.
(10) Using a ring installer, install the top ring with
the chamfer facing up (Fig. 17). The dot will be fac-
ing up.
(11) Position the gaps on the piston (Fig. 18):
²Oil spacer - Gap on center line of piston pin bore.
²Oil rails - Gap 180É apart on centerline of piston
skirt.
²No. 2 Compression ring - Gap 180É from top oil
rail gap.
²No. 1 Compression ring - Gap 180É from No. 2
compression ring gap.
CLEANING
Clean the cylinder bores thoroughly. Apply a light
film of clean engine oil to the bores with a clean lint-
free cloth.
INSTALLATION
(1) Install the piston rings on the pistons if re-
moved.
(2) Lubricate the piston and rings with clean en-
gine oil.
CAUTION: Ensure that connecting rod bolts do not
scratch the crankshaft journals or cylinder walls.Short pieces of rubber hose slipped over the con-
necting rod bolts will provide protection during in-
stallation.
(3) Use a piston ring compressor to install the con-
necting rod and piston assemblies through the top of
the cylinder bores (Fig. 19).
(4) Ensure the arrow on the piston top points to
the front of the engine (Fig. 19).
(5) Raise the vehicle.
Each bearing insert is fitted to its respective jour-
nal to obtain the specified clearance between the
bearing and the journal. In production, the select fit
is obtained by using various-sized, color-coded bear-
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
The rod journal is identified during the engine pro-
duction by a color-coded paint mark on the adjacent
cheek or counterweight toward the flange (rear) end
of the crankshaft. The color codes used to indicate
journal sizes are listed in the Connecting Rod Bear-
ing Fitting Chart.
When required, upper and lower bearing inserts of
different sizes may be used as a pair (refer to Con-
necting Rod Bearing Fitting Chart). A standard size
insert is sometimes used in combination with a 0.025
mm (0.001 inch) undersize insert to reduce clearance
0.013 mm (0.0005 inch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a ma-
chined surface adjacent to the oil squirt hole that
faces the camshaft side of the cylinder block.
(6) Install the connecting rod bearing caps and in-
serts in the same positions as removed.
Fig. 18 Ring Gap Position
Fig. 19 Rod and Piston Assembly Installation
9 - 44 2.5L ENGINEJ