1995 JEEP XJ air condition

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Front Suspension and Axle
3Rear Suspension and Axles
5Brakes
6Clutch
7Cooling System
8Electrical
9Engines
11Exhaust System and Intake Manifold
13Frame and Bumpers
14Fuel System
16Propeller Shafts
19Steering
21Transmission and Transfer Cases
22Wheels and Tires
23Body Components
24Heating and Air Conditioning
25Emission Control Systems
Index
Service Manual Comment Forms (Rear of Manual)

CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are clas-
sified according to standards recommended by the:
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
ENGINE OIL
API CERTIFICATION MARK
For maximum engine protection during all driving
conditions, install an engine oil that contains the API
Certification Mark (Fig. 2). The API Certification
Mark indicates that the oil is certified to meet the
most critical requirements established by the manu-
facturer.
Conformance to API specifications is determined by
tests that measure the ability of an oil to control:
²Engine wear.
²Bearing corrosion.
²Sludge.
²Varnish.
²Oil thickening.
²Rust.
²Piston deposits.
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
API SERVICE GRADE CERTIFIED
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use an engine oil that is API Service Grade Certi-
fied or an oil that conforms to the API Service Grade
SH or SH/CD. MOPAR provides engine oils that con-
form to all of these service grades.
GEAR LUBRICANTS
A dual grade is also used to specify the viscosity of
multi-purpose gear lubricants.
The API grade designation identifies gear lubri-
cants in terms of recommended usage.
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis and wheel bearing lubricants that are
recommended are identified by the NLGI Certifica-
tion Symbol. The symbol contains a coded designa-
tion. This identifies the usage and quality of the
lubricant.
The letter G within the symbol designates wheel
bearing lubricant. The letter L designates chassis lu-
bricant. When the letters are combined, the lubricant
can be used for dual applications. Use only lubricants
that display the NLGI Certification Symbol (Fig. 3).
LUBRICATION AND REPLACEMENT PARTS
RECOMMENDATION
Jeep vehicles are engineered to provide many years
of dependable operation. However, lubrication service
and maintenance are required for each vehicle. When
necessary, MOPARtbrand lubricants and genuine re-
placement parts are highly recommended. Each MO-
PAR brand lubricant and replacement part is
designed and to provide dependability and long ser-
vice life.
COMPONENTS REQUIRING NO LUBRICATION
There are many components that should not be lu-
bricated. The components that should not be lubri-
cated are:
²Air pumps.
²Generator bearings.
²Distributors.
²Drive belts.
²Drive belt idler pulleys.
²Rubber bushings.
²Starter motor bearings.
²Suspension strut bearings.
²Throttle control cables.
²Throttle linkage ball joints.
²Water pump bearings.
Fig. 2 The API Engine Oil Certification Mark
Fig. 3 NLGI Lubricant Container Certification/
Identification Symbol
0 - 2 LUBRICATION AND MAINTENANCEJ

MAINTENANCE SCHEDULES
INTRODUCTION
There are two maintenance schedules that show
proper service intervals for Jeep Cherokee and Jeep
Wrangler vehicles. Use the schedule that best de-
scribes the conditions the vehicle is operated under.
When mileage and time is listed, follow the interval
that occurs first.
ScheduleÐAlists all the scheduled maintenance
to be performed under normal operating conditions.
ScheduleÐBis a schedule for vehicles that are
usually operated under one or more of the following
conditions.
²Frequent short trip driving less than 5 miles (8
km).
²Frequent driving in dusty conditions.
²Trailer towing or heavy load hauling.
²Frequent long periods of engine idling.
²Sustained high speed operation.
²Desert operation.
²Frequent starting and stopping.
²Cold climate operation.
²Off road driving.
²Commercial service.
²Snow plow operation.
²More than half of vehicle operation occurs in
heavy city traffic during hot weather (above 90É F).
AT EACH STOP FOR GASOLINE
²Check engine oil level and add as required.
²Check windshield washer solvent and add as re-
quired.
ONCE A MONTH
²Check tire pressure and look for unusual tire wear
or damage.
²Check fluid levels of coolant reservoir, brake mas-
ter cylinder, power steering and transmission. Add
fluid as required.
²Check all lights and other electrical items for cor-
rect operation.
²Inspect battery and clean and tighten terminals as
required.
²Check rubber seals on each side of the radiator for
proper fit.
AT EACH OIL CHANGE
²Inspect exhaust system.
²Inspect brake hoses.
²Rotate the tires at each oil change interval shown
on ScheduleÐA: (7,500 Miles) or every other interval
shown on ScheduleÐB: (6,000 Miles).
²Check engine coolant level, hoses, and clamps.
²Lubricate 4x4 steering linkage.
²Lubricate propeller shaft universal joints and slip
spline, if equipped.After completion of off-road (4WD) operation, the
underside of the vehicle should be thoroughly in-
spected. Examine threaded fasteners for looseness.
HARSH SURFACE ENVIRONMENTS
After vehicle operation in a harsh surface environ-
ment, the following components should be inspected
and cleaned as soon as possible:
²Brake drums.
²Brake linings.
²Front wheel bearings (2WD vehicles only).
²Axle coupling joints.
This will prevent wear and/or unpredictable brake
action.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedule emission maintenance listed inbold
typeon the following schedules, must be done at the
mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
SCHEDULEÐA
7,500 MILES (12 000 KM) OR AT 6 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
15,000 MILES (24 000 KM) OR AT 12 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
22,500 MILES (36 000 KM) OR AT 18 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Inspect brake linings.
30,000 MILES (48 000 KM) OR AT 24 MONTHS
²Replace air cleaner element.
²Replace spark plugs.
²Adjust belt tension on non-automatic tensioning
drive belts.
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
0 - 4 LUBRICATION AND MAINTENANCEJ

120,000 MILES (192 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Replace spark plugs.
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
²Replace air cleaner element.
²Replace distributor cap and rotor.
²Replace ignition wires.
²Adjust or replace drive belts.
²Replace fuel filter. See note #1.²Drain and refill transfer case fluid.
NOTE 1:Not required for California vehicles, rec-
ommended for proper vehicle performance.
* Off-highway operation, trailer towing, taxi, limou-
sine, bus, snow plowing, or other types of commercial
service or prolonged operation with heavy loading,
especially in hot weather, require front and rear axle
service indicated witha*inScheduleÐB. Perform
these services if you usually operate your vehicle un-
der these conditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 8 LUBRICATION AND MAINTENANCEJ

ENGINE MAINTENANCE
INDEX
page page
Accessory Drive Belt....................... 21
Air Cleaner Element....................... 18
Air-Conditioner Compressor.................. 21
Battery................................. 20
Crankcase Ventilation System................ 19
Emission Control System................... 20
Engine Break-In.......................... 15
Engine Cooling System..................... 18
Engine Oil.............................. 15Engine Oil Change and Filter Replacement...... 16
Engine Oil Filter.......................... 17
Engine Supports.......................... 21
Exhaust System.......................... 21
Fuel Filter............................... 19
Fuel Usage StatementÐGas Engines.......... 19
Ignition Cables, Distributor Cap and Rotor....... 20
Rubber and Plastic Component Inspection....... 20
Spark Plugs............................. 20
ENGINE BREAK-IN
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
After first starting a new engine, allow it to idle for
15 seconds before shifting into a drive gear. Also:
²Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
²Avoid fast acceleration and sudden stops.
²Do not drive at full-throttle for extended periods of
time.
²Do not drive at constant speeds.
²Do not idle the engine excessively.
A special break-in engine oil is not required. The
original engine oil installed is a high quality, energy
conserving lubricant. Special break-in oils are not
recommended. These oils could interfere with the
normal piston ring seating process.
New engines tend to consume more fuel and oil un-
til after the break-in period has ended.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR GOV-
ERNMENT AGENCY FOR LOCATION OF COLLEC-
TION CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied or an oil that conforms to the API Service Grade
SH or SH/CD. MOPAR provides engine oils that con-
form to all of these service grades.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity grade of engine oil. SAE 30 specifies a single
viscosity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range. Select an engine oil that is best
suited to your particular temperature range and vari-
ation (Fig.1).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommeded for
gasoline engines. They are designated as either EN-
ERGY CONSERVING or ENERGY CONSERVING
II.
Fig. 1 Temperature/Engine Oil Viscosity
JLUBRICATION AND MAINTENANCE 0 - 15

ENGINE SUPPORTS
The general condition of the engine supports
should be inspected when engine compartment or un-
der vehicle service is performed.
INSPECTION
(1) Test the hardware that attaches the engine cyl-
inder block to the engine support brackets (Figs. 11
and 12) for the specified tightening torque.(2) Inspect the rubber in the engine support cush-
ions for softening and swelling. Slight surface deteri-
oration and wear at the ends will not affect the
functioning of an engine support.
ACCESSORY DRIVE BELT
Inspect and adjust drive belts at the interval de-
scribed in the Lubrication and Maintenance Sched-
ules. Refer to General Information section of this
group. For proper inspection and adjustment proce-
dures, see Group 7, Cooling System.
EXHAUST SYSTEM
The exhaust system should be inspected when un-
der vehicle service is performed or as specified in the
Lubrication and Maintenance Schedules.
INSPECTION
When inspecting an exhaust system, inspect for
cracked or loose joints, stripped screw/bolt threads,
corrosion damage, and worn or broken hangers
(Slight cracking in rubber isolator or hanger is ac-
ceptable). Replace all components that are corroded
or damaged. Do not attempt repair. Also, inspect for
the following obvious conditions and correct as neces-
sary:
²Exhaust system leaks, damage, misalignment.
²Contact with body panels metal or the frame.
²Catalytic converter bulging or excessive heat dam-
age.
CAUTION: A catalytic converter will become con-
taminated if leaded gasoline is burned in the en-
gine. If this occurs, the complete converter must be
replaced.
For proper service procedures see Group 11, Ex-
haust System and Intake Manifold.
AIR-CONDITIONER COMPRESSOR
LUBRICANT AND REFRIGERANT
The lubricant level in the air-conditioner compres-
sor should be checked if there are indications that oil
was lost. Loss of lubricating oil usually accompanies
a loss of refrigerant.
For additional information involving the A/C sys-
tem, refer to Group 24, Heater And Air Conditioning.
Fig. 11 Front Engine SupportÐTypical
Fig. 12 Rear Engine SupportÐTypical
JLUBRICATION AND MAINTENANCE 0 - 21

(5) Inspect the reservoir rubber diaphragm seal for
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak-
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE SYSTEMÐXJ VEHICLES
The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en-
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow
and possible reservoir damage when the pump mo-
tor energizes.
(3) The brake fluid level should be no lower than
the ADD indicator on the side of the reservoir (Fig.
8). If not, add brake fluid as necessary. Raise the
fluid level to the FULL indicator only. Do not over-fill
the reservoir.
(4) Turn the ignition switch OFF.
BRAKE SYSTEM INSPECTION
A brake system inspection should be included with
all brake service procedures, and also each time the
vehicle is lubricated.
(1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(2) Inspect brake pads and linings for contamina-
tion from brake fluid, and/or other fluids.
(3) Replace the brake pads linings if they are worn
to within 0.78 mm (1/32 in) of the rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for wear
or damage.
(6) Inspect the disc brake caliper dust boot for
damage and indications of brake fluid leakage. In-
spect the bushings and pins for corrosion, tears and a
binding condition.
(7) Pull the rear wheel cylinder dust boot back to
expose the wheel cylinder housing. Inspect for fluid
leaks. Inspect the pistons and cylinder bores.
(8) Inspect the brake differential warning valve
and housing for indications of leakage.
BRAKE FLUID HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
²Correct length
²Severe surface cracking
²Swelling
²Pulling
²Scuffing
²Excessively worn areas
If the hose has cracks or abrasions in the rub-
ber cover, the hose should be replaced.
(1) Inspect all the hoses for kinks, a distorted con-
dition and fluid leakage.
(2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against
any exhaust or other underbody components.
PARKING BRAKE
(1) Engage the parking brake pedal and then re-
lease it.
(2) Test it for smooth operation and vehicle-holding
capability.
(3) Inspect the parking brake cables.
(4) With the parking brake released, the rear
wheels should
rotate without restriction. Adjust the parking brake
cable tension, if necessary (Fig. 9 and 10).
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive the vehicle and test for proper brake ac-
tion.
Fig. 7 Reservoir Fluid LevelÐYJ (2.5L)
Fig. 8 Reservoir Fluid LevelÐYJ-XJ and Anti-Lock
Brake System
JLUBRICATION AND MAINTENANCE 0 - 31

(2) Note any indication of drum/rotor overheating,
wheel dragging or the vehicle pulling to one side
when the brakes are applied.
(3) Evaluate any performance complaints received
from the owner/operator.
(4) Repair the brake system as necessary. Refer to
Group, 5 Brakes for additional information and ser-
vice procedures.
TIRES
RECOMMENDED MAINTENANCE
The general condition of the tires and the inflation
pressures should be inspected at the same time the
engine oil is changed and the oil filter is replaced.
In addition, the tires/wheels should be rotated at
the intervals described in the Maintenance Schedules
section of this group.
INSPECTION
Inspect the tires for excessive wear, damage, etc.
Test the tires for the recommended inflation pres-sure. Refer to the tire inflation pressure decal located
on the inside of the glove box door, and also to Group
22, Tires And Wheels.
ROTATION
Refer to Group 22, Tires And Wheels for the recom-
mended method of tire/wheel rotation for a Jeep ve-
hicle.
BODY COMPONENTS
LUBRICATION REQUIREMENTS
All Jeep operating mechanisms and linkages
should be lubricated when necessary. The door
weatherstrip seals should be lubricated to prolong
their life as well as to improve door sealing.
LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat-
ing mechanisms should be:
²Inspected
²Cleaned
²Pivot/sliding contact areas on the mechanisms
should then be lubricated.
Multi-purpose NLGI GC-LB MOPAR Multi-Mileage
Lubricant or an equivalent, should be used to lubri-
cate the mechanisms. The door weatherstrip seals
should be lubricated with silicone lubricant spray.
Refer to the Body Lubricant Specifications chart be-
low for additional lubricant applications.
LUBRICATION
All pivoting and sliding contact areas, should be lu-
bricated periodically to ensure quiet, easy operation
and to protect against wear and corrosion. Areas in-
clude:
²Seat tracks.
²Door hinges/latches/strikers.
²Liftgate/tailgate/hood hinges (Fig. 11).
(1) As required, lubricate the body components
with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring):
²Spray a small amount of lock cylinder lubricant di-
rectly into the lock cylinder.
²Apply a small amount to the key and insert it into
the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.
Fig. 9 Park Brake Equalizer (XJ)ÐTypical
Fig. 10 Park Brake Equalizer (YJ)ÐTypical
0 - 32 LUBRICATION AND MAINTENANCEJ