1995 JEEP CHEROKEE torque

REMOVAL
(1) Remove the engine flywheel or converter drive
plate.
(2) Remove the oil pan.
(3) Remove the rear main bearing cap (No.7).
(4) Push the upper seal out of the groove. Ensure
that the crankshaft and seal groove are not damaged.
(5) Remove the lower half of the seal from the
bearing cap.
INSTALLATION
(1) Wipe the seal surface area of the crankshaft
until it is clean.
(2) Apply a thin coat of engine oil.
(3) Coat the lip of the seal with engine oil.
(4) Carefully position the upper seal into the
groove in the cylinder block. The lip of the seal faces
toward the front of the engine.
(5) Place the lower half of the seal into bearing cap
No.7 (Fig. 7).
(6) Coat the outer curved surface of the lower seal
with soap and the lip of the seal with engine oil (Fig. 7).
(7) Position the lower seal into the bearing cap re-
cess and seat it firmly. Be sure the seal is flush with
the cylinder block pan rail.
(8) Apply Loctite 518, or equivalent on the rear
bearing cap (Fig. 8). The bead should be 3 mm (0.125
in) thick. DO NOT apply Loctite 518, or equivalent to
the lip of the seal.
(9) Install the rear main bearing cap. DO NOT strike
the cap more than twice for proper engagement.
(10) Tighten all main bearing bolts to 108 Nzm (80
ft. lbs.) torque.
(11) Install the oil pan gasket and oil pan.(12) Install the engine flywheel or converter drive
plate.
CYLINDER BLOCK
Remove the Engine Assembly from the vehicle.
DISASSEMBLY
Refer to the applicable sections for detailed instruc-
tions.
(1) Drain the engine oil. Remove and discard the
oil filter.
(2) Remove the water pump from the cylinder block.
(3) Remove the vibration damper.
(4) Remove the timing case cover and lay the cover
upside down.
(5) Position a drift punch into the slot in the back
of the cover and tap the old seal out.
(6) Remove the oil slinger from crankshaft.
(7) Remove the camshaft retaining bolt and re-
move the sprockets and chain as an assembly.
(8) Remove the camshaft.
(9) Remove the oil pan and gasket.
(10) Remove the front and rear oil galley plugs.
(11) Remove the oil pump.
(12) Remove the connecting rods and the pistons.
Remove the connecting rod and piston assemblies
through the top of the cylinder bores.
(13) Remove the crankshaft.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole, the filter
bypass hole.
Fig. 7 Rear Main Bearing Oil Seal
Fig. 8 Location of Loctite 518 (or equivalent)
J4.0L ENGINE 9 - 91

²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the plugs to 41 Nzm (30 ft. lbs.) torque.
INSPECTIONÐCYLINDER BORE
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter (Fig. 12). To
correctly select the proper size piston, a cylinder bore
gauge, Special Tool 6879, capable of reading in .00019
INCREMENTS is required. If a bore gauge is not
available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen-
dicular (across or at 90 degrees) to the axis of the
crankshaft and then take two additional readings.
(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determine taper by subtracting the smaller di-
ameter from the larger diameter.
(5) Rotate measuring device 90É and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025 mm
(0.001 inch) and out-of-roundness does not exceed
0.025 mm (0.001 inch), the cylinder bore can be
honed. If the cylinder bore taper or out-of-round con-
dition exceeds these maximum limits, the cylinder
must be bored and then honed to accept an oversizepiston. A slight amount of taper always exists in the
cylinder bore after the engine has been in use for a
period of time.
HONINGÐCYLINDER BORE
The honing operation should be closely coordinated
with the fitting of pistons and rings. This will ensure
specified clearances are maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
ASSEMBLY
Refer to the applicable sections for detailed instruc-
tions.
(1) Install the crankshaft.
(2) Install the connecting rods and the pistons
through the top of the cylinder bores.
(3) Install the oil pump.
(4) Install the oil pan and gasket.
(5) Install the camshaft.
(6) Install the sprockets and chain as an assembly.
(7) Install the oil slinger from the crankshaft.
(8) Install the timing case cover seal.
(9) Install the timing case cover.
(10) Install the vibration damper.
(11) Install the water pump. Tighten the mounting
bolts to 31 Nzm (270 in. lbs.) torque.
(12) Lubricate the oil filter seal with clean engine
oil. Tighten oil filter to 18 Nzm (13 ft. lbs.) torque.
(13) Install the engine into the vehicle.
(14) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance).
(15) Fill the cooling system (refer to Group 7, Cool-
ing System for the proper procedures).
Fig. 12 Cylinder Bore Measurement
9 - 92 4.0L ENGINEJ

ENGINE SPECIFICATIONS (CONT.)
TORQUE SPECIFICATIONS
J4.0L ENGINE 9 - 95

EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM....................... 1
EXHAUST SYSTEM DIAGNOSIS............. 2SERVICE PROCEDURES................... 3
TORQUE SPECIFICATIONS................ 10
EXHAUST SYSTEM
GENERAL INFORMATION
The basic exhaust system consists of an engine ex-
haust manifold, exhaust pipe with oxygen sensor, cat-
alytic converter, exhaust heat shield(s), muffler and
exhaust tailpipe (Fig. 1).
The exhaust system uses a single muffler with a
single monolithic-type catalytic converter.
The 4.0L engines use a seal between the engine ex-
haust manifold and exhaust pipe to assure a tight
seal and strain free connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it may amplify objec-tionable noises originating from the engine or body.
When inspecting an exhaust system, critically in-
spect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to re-
pair.
When replacement is required, use original equip-
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
CATALYTIC CONVERTER
The stainless steel catalytic converter body is de-
signed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If un-
burned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid contami-
nating the catalyst core.
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both the
vehicle and the environment from the high tempera-
tures developed by the catalytic converter. The cata-
lytic converter releases additional heat into the
exhaust system. Under severe operating conditions,
the temperature increases in the area of the con-
Fig. 1 Typical Exhaust System
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
all parts.
(2) Use a new clamp and tighten the nuts to 61
Nzm (45 ft. lbs.) torque.
(3) Connect the exhaust pipe to the engine exhaust
manifold. Install a new seal between the exhaust
manifold and the exhaust pipe (4.0L engine, only).
Tighten the nuts to 31 Nzm (23 ft. lbs.) torque (Fig.
1).
(3) Install the rear crossmember. Tighten the
crossmember-to-sill bolts to 41 Nzm (30 ft. lbs.)
torque. Remove the support from the transmission.
(4) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
Nzm (35 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
EXHAUST PIPEÐYJ VEHICLES
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lu-
bricant (Fig. 4). Allow 5 minutes for penetration.(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 2).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Disconnect the exhaust pipe from the catalytic
converter and slide the pipe out of the transmission
torque arm insulator (Fig. 5). Remove the exhaust
pipe.
INSTALLATION
(1) Slide the exhaust pipe into the transmission
torque arm insulator and onto the catalytic converter
(Fig. 5).
(2) Clean the mating surface of the engine exhaust
manifold flange.
(3) Connect the exhaust pipe to the engine exhaust
manifold using new nuts. DO NOT tighten the nuts.
(4) Align the exhaust pipe.
(5) Use a new clamp at the exhaust pipe to cata-
lytic converter connection and tighten the nuts to 61
Nzm (45 ft. lbs.) torque.
(6) Tighten the exhaust pipe-to-engine exhaust
manifold nuts to 31 Nzm (23 ft. lbs.) torque.
(7) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
Nzm (35 ft. lbs.) torque.
(8) Lower the vehicle.
(9) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
CATALYTIC CONVERTER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
Fig. 4 Exhaust Pipe-to-Engine Exhaust Manifold
Bolts and Nuts
Fig. 5 Exhaust Pipe-to-Catalytic Converter
ConnectionÐYJ Vehicles
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

(2) Remove the clamp from the catalytic converter
and muffler connection (Fig. 6).
(3) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal
becomes cherry red.
(4) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(5) Disconnect the exhaust pipe from the catalytic
converter (Figs. 3 and 5). If needed, heat up the pipes
to separate.
INSTALLATION
(1) Connect the catalytic converter to the exhaust
pipe (Figs. 3 and 5). Use a new clamp and tighten
the nuts to 61 Nzm (45 ft. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install a new clamp at the muffler and catalytic
converter connection (Fig. 6). Tighten the clamp nuts
to 61 Nzm (45 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐXJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded to-
gether.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the rear exhaust tailpipe hanger clamp
(Fig. 7) and remove the exhaust tailpipe from the
front exhaust tailpipe hanger (Fig. 8).
(4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal be-
comes cherry red.
(5) While the metal is still cherry red, remove the
exhaust tailpipe/muffler assembly from the catalytic
converter.
(6) Remove the exhaust tailpipe from the muffler:
Fig. 6 Catalytic Converter-to-Muffler Connection
Fig. 7 Rear Exhaust Tailpipe Hanger Clamp
Fig. 8 Front Exhaust Tailpipe Hanger
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5

²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, apply heat until the metal becomes cherry
red. Remove the exhaust tailpipe/muffler clamp and
twist the exhaust tailpipe out of the muffler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly on
the rear exhaust tailpipe hanger. Make sure that the
exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front ex-
haust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-catalytic
converter clamp to 61 Nzm (45 ft. lbs.) torque (Fig. 6).
Tighten the nuts on the rear exhaust tailpipe clamp
to 14 Nzm (10 ft. lbs.) torque (Fig. 7).
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐYJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are clamped together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the exhaust tailpipe hanger/bracket
(Fig. 9).
(4) Remove the exhaust tailpipe from the front ex-
haust tailpipe hanger (Fig. 10).
(5) Heat the converter-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red.
(6) While the metal is still cherry red, place a
block of wood against the front of the muffler and
drive the muffler rearward to disengage.
(7) Remove the exhaust tailpipe/muffler assembly.
(8) Remove the exhaust tailpipe from the muffler:²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, remove the exhaust tailpipe/muffler clamp.
Heat the exhaust tailpipe-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red. While the metal is still cherry red, twist the ex-
haust tailpipe out of the muffler.
Fig. 9 Rear Exhaust Tailpipe Hanger/Bracket
Fig. 10 Front Exhaust Tailpipe Hanger
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

INSTALLATION
(1) Install the muffler onto the catalytic converter
outlet. Ensure that the locator on the converter
aligns with the notch on the muffler, if so equipped.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the muffler
outlet. Ensure that the locator on the exhaust
tailpipe aligns with the notch on the muffler, if so
equipped. Install the clamp and tighten the nuts fin-
ger tight.
(3) Install the front exhaust tailpipe supports and
the rear exhaust tailpipe hanger. Ensure that the ex-
haust tailpipe has sufficient clearance from the floor
pan and shields.
(4) Tighten the nuts on the muffler-to-catalytic
converter and the muffler-to-exhaust tailpipe clamps
to 61 Nzm (45 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and contact with the body panels and shields.
ENGINE EXHAUST MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove all components attached to the intake
manifold.
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 11).
(7) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 11).
CLEANING
Clean the intake and engine exhaust manifolds and
cylinder head mating surfaces.DO NOT allow for-eign material to enter either the intake mani-
fold or the ports in the cylinder head.
INSTALLATION
(1) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(2) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 11).
(3) Tighten bolt No.1 to 41 Nzm (30 ft. lbs.) torque
(Fig. 11).
(4) Install the intake manifold on the cylinder
head dowels (Fig. 11).
(5) Install bolts 2 through 5 (Fig. 11). Tighten
these bolts to 31 Nzm (23 ft. lbs.) torque.
(6) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 11).
(7) Tighten nuts 6 and 7 to 31 Nzm (23 ft. lbs.)
torque (Fig. 11).
(8) Install all components to the intake manifold.
(9) Raise the vehicle.
(10) Connect the exhaust pipe to the engine ex-
haust manifold. Tighten the bolts to 31 Nzm (23 ft.
lbs.) torque.
(11) Lower the vehicle.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
ENGINE EXHAUST MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The manifolds use a common gasket at the cylinder
head.
Refer to Intake ManifoldÐ4.0L Engine in this sec-
tion for the proper removal and installation proce-
dures.
INTAKE MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air inlet hose from the throttle
body and air cleaner.
(3) Loosen the accessory drive belt tension and re-
move the belt from the power steering pump.
(4) Remove the power steering pump and brackets
from the water pump and intake manifold. Support
power steering pump and bracket with mechanics
wire attached to the radiator upper crossmember.
(5) Remove the fuel tank filler cap to relieve the
fuel tank pressure.
(6) Install the fuel tank filler cap.
(7) Disconnect fuel supply and return tube from
the fuel rail (refer to Group 14, Fuel System - Quick
Connect Fittings).
(8) Disconnect the accelerator cable from the throt-
tle body and the holddown bracket.
Fig. 11 Intake/Engine Exhaust Manifold Installation
(2.5L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7