1995 JEEP CHEROKEE automatic transmission

REAR LIGHTING
TAIL LAMPS AND REAR LICENSE PLATE LAMPS
Circuit A3 from fuse 5 in the Power Distribution
Center (PDC) connects to a bus bar in the fuse block
which feeds circuit L7. Fuse 9 in the fuse block pro-
tects circuit L7.
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF, plus a dimmer
switch. When the headlamp switch is in the PARK or
ON position, the switch connects circuit L7 to circuit
L90. From the headlamp switch, circuit L90 branches
to power the front parking lamps and rear tail
lamps, side marker lamps, and rear license plate
lamps.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
tail lamps, and rear license plate lamps.
HELPFUL INFORMATION
²Check fuse 5 in PDC.
²Check fuse 9 in the fuse block.
²When the headlamp switch is in the PARK or ON
position, circuit L7 also connects to circuit E2. Cir-
cuit E2 continues through fuse 25 in the fuse block.
Circuit E2 powers the illumination lamps.
STOP LAMPS AND CHMSL LAMPS
Circuit L9 from fuse 4 in the Power Distribution
Center (PDC) connects to the stop lamp switch.
When the operator depresses the brake pedal, the
stop lamp switch closes and connects circuit L9 to
circuit L50. Circuit L50 connects to the stop lamps
and center high mounted stop lamps (CHMSL). Cir-
cuit Z1 provides a ground for the stop lamps.
HELPFUL INFORMATION
²Check fuses 13 in the PDC.
²Check for continuity across the stop lamp switch
when it is closed.
BACK-UP LAMPS
In the START or RUN position, the ignition switch
connects circuit A1 from fuse 6 in the Power Distri-
bution Center (PDC) to circuit A21. Circuit A21 feeds
a bus bar in the PDC that powers circuit F12
through fuse 11.
Circuit F12 supplies power to the back-up lamp
switch. On automatic transmission equipped vehicles,
the back-up lamp switch is part of an assembly that
includes the PARK/NEUTRAL position switch. When
the operator puts the transmission in REVERSE, the
back-up lamp switch connects circuit F12 to circuit
L10. Circuit L10 feeds the back-up lamps. Circuit Z1
provides ground for the back-up lamps.
HELPFUL INFORMATION
²Check fuses 6 and 11 in the PDC.
²Check for continuity across the back-up lamp
switch when it is closed.
DIAGRAM INDEX
Component Page
Center High Mounted Stop Lamps (CHMSL).......8W-51-3
Fuse 4 (PDC)...........................8W-51-3
Fuse 5 (PDC)...........................8W-51-2
Fuse 6 (Fuse Block).......................8W-51-2
Fuse 6 (PDC)...........................8W-51-2
Fuse 9 (Fuse Block).......................8W-51-2
Headlamp Switch.........................8W-51-2
Ignition Switch..........................8W-51-2
Left Back-Up Lamp.......................8W-51-4
Left Side Marker Lamp.....................8W-51-4
Left Tail/Stop Lamp.......................8W-51-4
Left Turn Signal Lamp.....................8W-51-4
License Plate Lamp.......................8W-51-3
Park/Neutral Position Switch.................8W-51-2
Right Back-Up Lamp......................8W-51-5
Right Side Marker Lamp....................8W-51-5
Right Tail/Stop Lamp......................8W-51-4
Right Turn Signal Lamp....................8W-51-5
Stop Lamp Switch........................8W-51-3
J8W-51 REAR LIGHTINGÐXJ-RHD 8W - 51 - 1

INSTALLATIONÐYJ VEHICLES
(1) If the engine support bracket was removed, po-
sition the bracket onto the block and install the at-
taching bolts (Fig. 9). Tighten the bolts to 62 Nzm (46
ft. lbs.) torque.
(2) Place the support cushion on the support cush-
ion bracket (Fig. 9). Install the support cushion re-
taining bolts and nuts. Tighten the bolts and nuts to
52 Nzm (38 ft. lbs.) torque.
(3) Install the through bolt and the retaining nut
(Fig. 9). Tighten the through bolt nut to 69 Nzm (51
ft. lbs.) torque.
(4) Remove the engine support.
(5) Lower the vehicle.
(6) Connect negative cable to battery.
ENGINE MOUNTÐREAR
A resilient rubber cushion supports the transmis-
sion at the rear between the transmission extension
housing and the rear support crossmember or skid
plate.
REMOVALÐXJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle and support the transmission.
(3) Remove the nuts holding the support cushion to
the crossmember (Figs. 10 and 11). Remove the cross-
member.
(4)MANUAL TRANSMISSION:
(a) Remove the support cushion nuts and remove
the cushion.
(b) If necessary, remove the bolts holding the
transmission support bracket to the transmission
(Fig. 10). Remove the bracket.
(5)AUTOMATIC TRANSMISSION:
(a) Remove the support cushion bolts and remove
the cushion and the transmission support bracket.(b) If necessary on 2WD vehicles, remove the
bolts holding the transmission support adaptor
bracket to the transmission (Fig. 11). Remove the
adaptor bracket.
INSTALLATIONÐXJ VEHICLES
(1)MANUAL TRANSMISSION:
(a) If removed, position the transmission support
bracket to the transmission and install the bolts.
Tighten the bolts to 43 Nzm (32 ft. lbs.) torque.
(b) Position the support cushion onto the trans-
mission support bracket. Install and tighten the
nuts to 46 Nzm (34 ft. lbs.) torque.
(2)AUTOMATIC TRANSMISSION:
(a) If removed, position the transmission support
adaptor bracket (2WD vehicles) to the transmission
and install the bolts. Tighten the bolts to 75 Nzm
(55 ft. lbs.) torque.
(b) Position the transmission support bracket
and support cushion to the transmission and install
the bolts. Tighten the bolts to 75 Nzm (55 ft. lbs.)
torque.
(3) Position the crossmember onto the support
cushion studs and install the nuts. Tighten the nuts
to 22 Nzm (192 in. lbs.) torque.
(4) Install the crossmember to sill bolts and
tighten to 41 Nzm (30 ft. lbs.) torque.
Fig. 10 Rear MountÐXJ Vehicles (Manual
Transmission)
Fig. 11 Rear MountÐXJ Vehicles (Automatic
Transmission)
9 - 16 2.5L ENGINEJ

(5) Remove the transmission support.
(6) Lower the vehicle.
(7) Connect negative cable to battery.
REMOVALÐYJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle and support the transmission.
(3) Remove the nuts holding the support cushion to
the skid plate (Figs. 12 and 13).
(4) Remove the skid plate bolts and the skid plate.
(5)MANUAL TRANSMISSION:
(a) Remove the bolts holding the support cushion
and torque arm bracket to the transmission (Fig.
12).
(b) Remove the support cushion and torque arm
bracket.
(6)AUTOMATIC TRANSMISSION:
(a) Remove the bolts and nuts holding the sup-
port cushion to the torque arm bracket (Fig 13).
Remove the support cushion.
(b) Remove the bolts holding the torque arm
bracket to the transmission (Fig. 13). Remove the
torque arm bracket.
INSTALLATIONÐYJ VEHICLES
(1)MANUAL TRANSMISSION:
(a) Position the torque arm bracket and support
cushion to the transmission and install the bolts
(Fig. 12).
(b) Tighten the bolts to 54 Nzm (40 ft. lbs.)
torque.
(2)AUTOMATIC TRANSMISSION:
(a) Position the torque arm bracket to the trans-
mission and install the bolts. Tighten the bolts to
54 Nzm (40 ft. lbs.) torque.
(b) Position the support cushion to the torque
arm bracket and install the bolts and nuts. Tighten
the nuts to 54 Nzm (40 ft. lbs.) torque.(3) Position the skid plate to the studs of the sup-
port cushion and install the nuts (Figs. 12 and 13).
Tighten the stud nuts to 54 Nzm (40 ft. lbs.) torque.
(4) Install the skid plate bolts to the sill and
tighten to 88 Nzm (65 ft. lbs.) torque.
(5) Remove the transmission support.
(6) Lower the vehicle.
(7) Connect negative cable to battery.
ENGINE DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the top and bottom damper nuts (Fig.
14).
(3) Remove the outer retainers and bushings (Fig.
14).
(4) Remove the top damper bracket nut and bolts
(Fig. 14).
(5) Remove the bracket, inner retainers, bushings
and the damper (Fig. 14).
INSTALLATION
(1) Install the damper on the lower bracket with
the lower inner retainer and bushing in place.
Fig. 12 Rear MountÐYJ Vehicles (Manual
Transmission)
Fig. 13 Rear MountÐYJ Vehicles (Automatic
Transmission)
J2.5L ENGINE 9 - 17

(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

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

tor in the Component Removal/Installation section of
Group 8D, Ignition Systems.
(14) Install the distributor and ignition wires. Re-
fer to Distributor in the Component Removal/Instal-
lation section of Group 8D, Ignition Systems.
(15) Install the radiator or radiator and condenser,
if equipped with A/C.
(16) Fill the cooling system.
(17) Connect negative cable to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain the radiator. DO NOT waste reusable
coolant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
(4) Disconnect the radiator overflow tube, radiator
hoses, automatic transmission fluid cooler pipes (if
equipped).
(5) Remove the radiator.
(6) If equipped with air conditioning:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpentine drive
belt idler pulley.
(b) Disconnect and remove the generator.
(c) Remove the A/C condenser attaching bolts
and move the condenser and receiver/drier assem-
bly up and out of the way.
(7) Remove the serpentine drive belt.
(8) Remove the crankshaft vibration damper.
(9) Remove the timing case cover. Clean the gasket
material from the cover.
(10) Rotate crankshaft until the crankshaft
sprocket timing mark is closest to and on the center
line with the camshaft sprocket timing mark (Fig.
12).
(11) Remove camshaft sprocket retaining bolt.
(12) Remove the crankshaft oil slinger.
(13) Remove the sprockets and chain as an assem-
bly (Fig. 13).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) Inspect the damaged camshaft pin.(15) If the pin is a spring-type pin, remove the bro-
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.
(16) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: Cover the opened oil pan area to prevent
metal chips from entering the pan.
(17) Drill into the pin center witha4mm(5/32
inch) drill bit.
(18) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled, bab-
bitt-lined bearings that are pressed into the cylinder
block and then line reamed. The camshaft bearing
bores and bearing diameters are not the same size.
They are stepped down in 0.254 mm (0.010 inch) in-
crements from the front bearing (largest) to the rear
Fig. 12 Timing Chain Alignment
Fig. 13 Camshaft and Crankshaft Sprocket and
Chain
9 - 34 2.5L ENGINEJ