1995 JEEP YJ body procedures

CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to at
least 12.4 volts (75%charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
²Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
PORTABLE STARTING UNIT
There are many types of portable starting units
available for starting engines. Follow the manufac-
turer's instructions and observe the listed precau-
tions when involved in any engine starting
procedure.
HOISTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a Jeep vehicle (Fig. 2 and 3). Support the ve-
hicle in the raised position with jack stands at the
front and rear ends of the frame rails.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
Use the correct sub-frame rail or frame rail
lifting locations only (Fig. 2 and 3).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
When a frame-contact type hoist is used, ver-
ify that the lifting pads are positioned properly
(Fig. 2 and 3).WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING DE-
VICE WHEN THESE CONDITIONS EXIST.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all Jeep vehi-
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use a tow dolly under the opposite end
of the vehicle. A vehicle with flat-bed device can also
be used to transport a disabled vehicle (Fig. 4).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
²Secure loose and protruding parts.
²Always use a safety chain system that is indepen-
dent of the lifting and towing equipment.
²Do not allow towing equipment to contact the dis-
abled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
Fig. 2 Vehicle Lifting LocationsÐTypical
0 - 10 LUBRICATION AND MAINTENANCEJ

(2) Remove the air cleaner element from the body/
housing.
(3) Hold a shop light on throttle body side of ele-
ment. Inspect air intake side of element. If element
is saturated with oil or light is not visible, replace fil-
ter. If element is saturated with oil, perform crank-
case ventilation system tests.
(4) Wash the air cleaner cover and body/housing
(Fig. 10) with cleaning solvent and wipe dry.
(5) Install the air cleaner element and attach the
cover to the body/housing.
CRANKCASE VENTILATION SYSTEM
All Jeep 2.5L and 4.0L engines are equipped with a
crankcase ventilation (CCV) system. Refer to Group
25 Emissions, for additional information.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System.
FUEL USAGE STATEMENTÐGAS ENGINES
Jeep vehicles are designed to meet all emission reg-
ulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines having a minimum posted octane of 87.
If a Jeep vehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm-
ful. However,continued heavy knock at high
speeds can cause damage and should be
checked immediately.
In addition to using unleaded gasoline with the
proper octane rating,those that contain deter-
gents, corrosion and stability additives are rec-
ommended.Using gasolines that have these
additives will help improve fuel economy, reduce
emissions and maintain vehicle performance.
Poor quality gasolinecan cause problems such
as hard starting, stalling and stumble. If these prob-
lems occur, use another brand of gasoline before con-
sidering servicing the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally
used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline.Gasoline with ethanol may be
used in your vehicle.
METHANOL
CAUTION: Do not use gasolines containing metha-
nol. Use of methanol/gasoline blends may result in
starting and driveability problems. In addition, dam-
age may be done to critical fuel system compo-
nents.
Methanol (Methyl or Wood Alcohol) is used in a va-
riety of concentrations blended with unleaded gaso-
Fig. 9 Air Cleaner & Filter ElementÐ2.5L and 4.0L
Engines
Fig. 10 Air Cleaner Body/Housing & Cover
JLUBRICATION AND MAINTENANCE 0 - 19

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

(11) Remove the support and lower the vehicle.
DRIVE SHAFTS
Lubricate at the intervals described in the Mainte-
nance Schedule section of this Group. Refer to Group
16, Propeller Shafts for proper service procedures.
CAUTION: It is very important that drive shafts be
lubricated at periodic intervals and that the speci-
fied type of lubricant be used. Failure to properly
lubricate could result in premature wear of drive
shaft components.
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or any lubricate
that is identified as NLGI GC-LB lubricant.
RUBBER AND PLASTIC HOSES/TUBING
The condition of underbody rubber hose and plastic
tubing should be inspected whenever underbody ser-
vice is performed.
Rubber hoses and plastic tubing should be re-
placed immediately if there is any evidence of
failure.
HOSE/TUBING INSPECTION
(1) Inspect all hose and tubing fittings for loose-
ness and corrosion. Inspect the rubber hoses for brit-
tleness and cracks. Thoroughly inspect the hose ends
(those that are slipped over nipple connectors) for
splits (Fig. 10, 11, 12, 13, 14, 15 and 16).
(2) Inspect the surface of hoses and tubing for heat
and mechanical damage. Hose and tubing located
close to an exhaust pipe should be given special at-
tention.
(3) Inspect the rubber hose routing to ensure that
the hoses do not contact any heat source, moving
component, etc., that would potentially cause heat or
mechanical damage.
(4) Inspect all the hose connections to ensure that
they are secure and there is no fluid leakage. Actual
dripping of hot fluid should be noted and the clamps
tightened in an attempt to stop the leakage before re-
placing the hose.
Fig. 10 Front Axle Vent Hose (4WD)ÐXJ Vehicles
Fig. 9 Differential Housing Cover Installed
Fig. 11 Front Axle Vent HoseÐYJ Vehicles
0 - 26 LUBRICATION AND MAINTENANCEJ

CHASSIS AND BODY COMPONENTS
INDEX
page page
Body Components........................ 32
Chassis Component and Wheel Bearing
Lubricants............................. 28
Front Wheel Bearings...................... 28
Headlamps.............................. 33
Manual Steering Gear...................... 30Power Brake System....................... 30
Power Steering System..................... 29
Speedometer Cable....................... 33
Steering Linkage.......................... 28
Tires................................... 32
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis component and wheel bearing lubri-
cants that are recommended for Jeep vehicles are
identified by the NLGI Certification Symbol (Fig. 1).
The symbol contains a coded designation that identi-
fies the usage and quality of the lubricant.
The letterGdesignates wheel bearing lubricant.
LetterLdesignates chassis lubricant. When the let-
ters are combined the lubricant can be used for dual
applications. The suffix lettersCandBdesignate the
level of the lubricant for the application. The letterC
represents level available for wheel bearing lubricant
(G) and the letterBrepresents level available for
chassis lubricant (L).
STEERING LINKAGE
The steering linkage (Fig. 2) should be lubricated
and inspected at the intervals described in the Main-
tenance Schedules section of this Group. Refer to
Group 2, Front Suspension and Axles for proper ser-
vice procedures.
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or NLGI GC-LB
lubricant equivalent to lubricate the steering linkage.
INSPECTION
(1) Inspect the steering linkage. Examine the tie
rods and the drag link for bending, and the ball
studs for looseness and excessive wear.(2) Replace, as necessary, all torn/ruptured ball-
stud seals and damaged/defective steering linkage
components.
CAUTION: Use care to prevent lubricant from con-
tacting the brake rotors.
FRONT WHEEL BEARINGS
Some 2WD XJ vehicles are equipped with service-
able front wheel bearings. XJ 4WD vehicles have
semi-floating axle shafts and axle shaft bearings that
are lubricated via differential lube oil.
RECOMMENDED MAINTENANCEÐ2WD XJ
VEHICLES
If equipped, the serviceable front wheel bearings
should be lubricated (re-packed) at the same time as
front brake pad/caliper service is conducted.
LUBRICANT SPECIFICATION
Wheel bearings should be lubricated with a lubri-
cant that is identified as NLGI GC-LB lubricant.
INSPECTION/LUBRICATION
(1) Remove the wheel/tire and the disc brake cali-
per.Do not disconnect the caliper brake fluid
Fig. 1 NLGI Lubricant Container Certification/
Identification Symbol
Fig. 2 Steering Components (XJ)ÐTypical
0 - 28 LUBRICATION AND MAINTENANCEJ

(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

(5) Extra close attention should also be given to
the hood latch components to ensure proper function-
ing.
HEADLAMPS
MAINTENANCE SCHEDULE
Every six months check the headlamp beams to en-
sure that the headlamp beams are correctly posi-
tioned.
AIM ADJUSTMENT
Refer to Group 8L, Lamps for headlamp aim ad-
justment procedures.
SPEEDOMETER CABLE
SERVICE INFORMATION
Speedometer cable lubrication is not necessary. For
service information involving noisy cables, refer to
Group 8E, Instrument Panel and Gauges.
BODY LUBRICANT SPECIFICATIONS
Fig. 11 Hood Hinge LubricationÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 33