1995 JEEP YJ Service And Repair Manual

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Page 1289 of 2158

JEEP YJ 1995 Service And Repair Manual SERVICE DIAGNOSISÐPERFORMANCEÐCONT.
9 - 10 ENGINESJ

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JEEP YJ 1995 Service And Repair Manual SERVICE DIAGNOSISÐMECHANICAL
JENGINES 9 - 11

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JEEP YJ 1995 Service And Repair Manual SERVICE DIAGNOSISÐLUBRICATION
9 - 12 ENGINESJ

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JEEP YJ 1995 Service And Repair Manual 2.5L ENGINE SERVICE PROCEDURES
INDEX
page page
Camshaft............................... 32
Camshaft Pin Replacement.................. 34
Engine AssemblyÐXJ Vehicles............... 18
Engine AssemblyÐ

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JEEP YJ 1995 Service And Repair Manual The digits of the code identify:
(1) 1st DigitÐThe year (4 = 1994).
(2) 2nd & 3rd DigitsÐThe month (01 - 12).
(3) 4th & 5th DigitsÐThe engine type/fuel system/
compression ratio (HX = A 2.5 liter (

The digits of the code identify:
(1) 1st DigitÐThe year (4 = 1994).
(2) 2nd & 3rd DigitsÐThe month (01 - 12).
(3) 4th & 5th DigitsÐThe engine type/fuel system/
compression ratio (HX = A 2.5 liter (150 CID) 9.1:1
compression ratio engine with a multi-point fuel in-
jection system).
(4) 6th & 7th DigitsÐThe day of engine build (01 -
31).
FOR EXAMPLE:Code * 401HX23 * identifies a
2.5 liter (150 CID) engine with a multi-point fuel in-
jection system, 9.1:1 compression ratio and built on
January 23, 1994.
OVERSIZE AND UNDERSIZE COMPONENT
CODES
Some engines may be built with oversize or under-
size components such as:
²Oversize cylinder bores.
²Oversize camshaft bearing bores.
²Undersize crankshaft main bearing journals.
²Undersize connecting rod journals.
These engines are identified by a letter code (Fig.
4) stamped on the oil filter boss near the distributor
(Fig. 5).
ENGINE MOUNTSÐFRONT
The front mounts support the engine at each side.
These supports are made of resilient rubber.
REMOVALÐXJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Support the engine.
(4) Remove through bolt nut (Fig. 6). DO NOT re-
move the through bolt.
(5) Remove the retaining bolts and nuts from the
support cushions (Fig. 6).
(6) Remove the through bolt.
(7) Remove the support cushions.
INSTALLATIONÐXJ VEHICLES
(1) If the engine support bracket was removed, po-
sition the LEFT bracket (Fig. 6) and the RIGHT
bracket with generator brace (Fig. 7) onto the cylin-
der block. Install the bolts and stud nuts.
(a) RIGHT SIDE (Fig. 7)ÐTighten the bolts to 61
Nzm (45 ft. lbs.) torque. Tighten the stud nuts to 46
Nzm (34 ft. lbs.) torque.
(b) LEFT SIDE (Fig. 6)ÐTighten the bolts to 61
Nzm (45 ft. lbs.) torque.
(2) If the support cushion brackets were removed,
position the brackets onto the lower front sill (Figs. 6
and 8). Install the bolts and stud nuts. Tighten the
bolts to 54 Nzm (40 ft. lbs.) torque and the stud nuts
to 41 Nzm (30 ft. lbs.) torque.
(3) Place the support cushions onto the support
cushion brackets (Fig. 6). Tighten the right support
cushion nuts to 65 Nzm (48 ft. lbs.) torque. Tighten
the left support cushion bolt and nut to 41 Nzm (30
ft. lbs.) torque.
Fig. 4 Oversize and Undersize Component Codes
Fig. 5 Oversize and Undersize Component Code
Location
9 - 14 2.5L ENGINEJ

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JEEP YJ 1995 Service And Repair Manual (4) Install the through bolt and the retaining nut
(Fig. 6). Tighten the through bolt nut to 65 Nzm (48
ft. lbs.) torque.
(5) Remove the engine support.
(6) Lower the vehicle.
(7) Connect negative cab

Page 1295 of 2158

JEEP YJ 1995 Service And Repair Manual 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.) tor

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

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JEEP YJ 1995 Service And Repair Manual (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 th

(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

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