1995 JEEP XJ tow

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
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Fig. 1).
(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 fromthe engine. Make sure the tension spring and thrust
pin do not fall out of the preload bolt.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 2).
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 seal
area 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. Make sure the tension
spring and thrust pin are in place in the camshaft
preload bolt.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 3).
(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.Fig. 1 Vibration Damper Removal Tool 7697
Fig. 2 Timing Case Cover Components
9 - 72 4.0L ENGINEJ

(10) Using a ring installer, install the top ring with
the chamfer facing up (Fig. 16). The dot will be fac-
ing up.
(11) Position the gaps on the piston (Fig. 17):
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
connecting rod bolts will provide protection during
installation.(3) Use a piston ring compressor to install the con-
necting rod and piston assemblies through the top of
the cylinder bores (Fig. 18).
(4) Ensure the arrow on the piston top points to
the front of the engine (Fig. 18).
(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.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(7) Install the oil pan and gaskets as outlined in
the installation procedure.
Fig. 17 Ring Gap Position
Fig. 18 Rod and Piston Assembly Installation
9 - 86 4.0L ENGINEJ

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

TRANSFER CASE SKID PLATE
REMOVAL
(1) Support the skid plate.
(2) Remove the bolts that attach the skid plate to
the transmission support crossmember and frame sill
(Fig. 4).
(3) Remove the support and skid plate from the ve-
hicle.
INSTALLATION
(1) Position and support the skid plate at the
frame sill and transmission support crossmember
(Fig. 4).(2) Attach the skid plate to the frame sill and
crossmember with bolts. Tighten bolts to 22 Nzm (16
ft. lbs.) torque.
FUEL TANK SKID PLATE
REMOVAL
(1) Position a support under skid plate.
(2) Remove the bolts that attach skid plate to un-
derbody side rails (Fig. 5 and 6).
(3) Remove the support and the skid plate from
the vehicle.
INSTALLATION
(1) Position and support skid plate under fuel
tank.
(2) Install bolts to attach the skid plate to under-
body rails. Tighten the bolts to 50 Nzm (37 ft. lbs.)
torque.
(3) Remove the support from under skid plate.
Fig. 3 Front Skid Plate Removal/Installation
Fig. 4 Transfer Case Skid Plate
Fig. 5 Fuel Tank Skid Plate W/O Trailer Hitch Or Tow
Hook
Fig. 6 Fuel Tank Skid Plate With Trailer Hitch Or
Tow Hook
JXJÐFRAME 13 - 3

BUMPERS
INDEX
page page
Front Bumper............................. 5
Front Tow Hooks........................... 7Rear Bumper............................. 8
Rear Tow Hook............................ 9
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks can
be removed from XJ front bumpers with the bumper at-
tached to the vehicle. Do not remove the bumper from
the vehicle if only these components require service.
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.(2) Disconnect the fog lamp wire harness connec-
tors, if equipped (Fig. 1).
(3) Disconnect the vacuum reservoir tube harness
connectors (Fig. 2 and 3).
(4) Remove the locknuts and Torx-head bolts that
attach the tow hook straps (Fig. 4) to the underbody
sillmember.
Fig. 1 Fog Lamp Wire Harness Connector
Fig. 2 Vacuum ReservoirÐLeft Side
Fig. 3 Vacuum ReservoirÐRight Side With Speed
Control Only
Fig. 4 Tow Hook & StrapÐXJ Vehicles
JXJÐBUMPERS 13 - 5

The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(5) Detach the tow hook straps from the sillmem-
ber.
(6) Support the bumper.
(7) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers (Fig.
5).
(8) Remove the support and the bumper from the
vehicle (Fig. 5).
(9) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(10) Remove the support brackets (Fig. 6), bumper
guards (Fig. 7) and caps (Fig. 8) from the bumper
rail.(11) Remove the license plate bracket (Fig. 9), if
equipped, from the bumper rail.
Fig. 5 Front Bumper Removal/Installation
Fig. 6 Bumper Support Bracket Removal/Installation
Fig. 7 Bumper Guard Removal/Installation
Fig. 8 Bumper End Cap Removal/Installation
Fig. 9 Bumper License Plate Bracket Removal/
Installation
13 - 6 XJÐBUMPERSJ

(12) Remove the fog lamps (Fig. 10) from the
bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement brackets from the sillmembers.
ASSEMBLY/INSTALLATION
(1) If removed, install the sill crossmember rein-
forcement brackets on the sillmembers (Fig. 11).
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If equipped, install the bumper support brack-
ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in (Fig. 6).
Tighten the locknuts with 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(4) Install tow hooks. Tighten nuts with 100 Nzm
(74 ft. lbs.) torque.
(5) Install the bumper end caps on the bumper
rail. Tighten nuts with 8 Nzm (72 in. lbs.) torque.(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
(7) Install the fog lamps on the bumper rail.
Tighten the nuts to 20 Nzm (15 ft. lbs.) torque.
(8) If removed, install the vacuum reservoir(s) on
the bumper rail. Tighten the retaining screws and
bolts to 8 Nzm (72 in. lbs.) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(11) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts with 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(12) Connect the fog lamp wire harness connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
FRONT TOW HOOKS
If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 Nzm (74 ft. lbs.)
torque.
If a tow hook/bumper support bracket must be re-
placed, refer to the following removal and installation
procedures.
REMOVAL
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.
(1) Disconnect the fog lamp wire harness connec-
tors, if equipped.
(2) Disconnect the vacuum reservoir tube harness
connectors.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers.
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem-
ber.
The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(6) Detach the tow hook straps from the sillmem-
ber.
(7) Remove the support and the bumper from the
vehicle.
(8) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(9) Remove the tow hook from the bumper support
bracket.
Fig. 10 Fog Lamp
Fig. 11 Reinforcement Brackets
JXJÐBUMPERS 13 - 7

(10) Remove the support bracket from the bumper
rail.
INSTALLATION
(1) Install the bumper guard and bumper support
bracket on the bumper rail. Tighten the retaining
hardware in the sequence indicated in Figure 7.
Tighten locknuts to 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If not equipped with bumper guards, install the
bumper support bracket on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(3) Position the tow hook at the support bracket.
Install the bolts and nuts that attach tow hook to the
bumper support bracket. Tighten nuts to 100 Nzm (74
ft. lbs.) torque.
(4) Position and support the bumper at the front of
the vehicle.
(5) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(6) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts to 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(7) Connect the fog lamp wire harness connectors.
Connect the vacuum reservoir tube harness connec-
tors.
(8) Remove the bumper support.
REAR BUMPER
REMOVAL
(1) For vehicles equipped with a trailer hitch, re-
move the hitch before removing the bumper. If neces-
sary, refer to the removal procedure within Group 23,
Body Components.
(2) Raise and support the rear of the vehicle.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the sill crossmember (Fig. 12).
(5) Remove the support and the rear bumper from
the vehicle.
(6) Remove the bumper support brackets and
splash shield the bumper, if necessary (Fig. 13).
(7) Remove the bumper end caps (Fig. 14) and
bumper guards from the bumper (Fig. 15), if neces-
sary.
INSTALLATION
(1) As applicable, install the splash shield and
bumper support brackets, the bumper end caps and
the bumper guards.
(2) Tighten the bumper support bolts to 56 Nzm (41
ft. lbs.).(3) Tighten the nuts in the sequence depicted in
Figure 14. Tighten the bumper end cap plate bolt
Fig. 12 Rear Bumper Removal/InstallationÐXJ
Vehicles
Fig. 13 Bumper Bracket & Splash Shield Removal/
InstallationÐXJ Vehicles
Fig. 14 Bumper End Cap Removal/InstallationÐXJ
Vehicles
13 - 8 XJÐBUMPERSJ