wheel alignment JEEP CHEROKEE 1995 Service Owner's Manual

CAUTION: On some models, two bolts are used to
secure the sensor to the transmission. These bolts
are specially machined to correctly space the unit
to the flywheel. Do not attempt to install any other
bolts.
(3) Connect the electrical connector to the sensor.
(4) Install clip on sensor wire harness.
(5) Install clip over fuel rail mounting stud. Install
clip mounting nut.
INSTALLATIONÐYJ MODELS WITH 4.0L
6-CYLINDER ENGINE AND AUTOMATIC
TRANSMISSION
(1) Install the sensor into the access hole on the
transmission.
(2) Install sensor mounting bolt (Fig. 6).
(3) Tighten sensor mounting bolt to 6-to-8 Nzm (50-
to-70 in. lbs.) torque.
(4) Connect the electrical connector to sensor.
(5) Install the clip to sensor wire harness.
(6) Install clip over fuel rail mounting stud. Install
clip mounting nut.
ENGINE COOLANT TEMPERATURE SENSOR
For an operational description, diagnosis and re-
moval/installation procedures, refer to Group 14,
Fuel System.
DISTRIBUTOR
GENERAL INFORMATION
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
Factory replacement distributors are equipped with
a plastic alignment pin already installed. The pin is
located in an access hole on the bottom of the distrib-
utor housing (Fig. 7). It is used to temporarily lock
the rotor to the cylinder number 1 position during in-
stallation. The pin must be removed after installing
the distributor.
The camshaft position sensor is located in the dis-
tributor on all engines (Fig. 8). For removal/installa-
tion procedures, refer to Camshaft Position Sensor.
Distributor removal is not necessary for sensor re-
moval.
Refer to figure 8 for an exploded view of the dis-
tributor.
A fork with a slot is supplied on the bottom of the
distributor housing where the housing base seats
against the engine block (Fig. 8). The centerline of
the slot aligns with the distributor holddown bolt
hole in the engine block. Because of the fork, the dis-
tributor cannot be rotated. Distributor rotation is not
necessary as all ignition timing requirements are
handled by the powertrain control module (PCM).The position of the distributor determines fuel syn-
chronization only. It does not determine ignition tim-
ing.
Do not attempt to modify this fork to attain
ignition timing.
Fig. 7 Plastic Alignment Pin
Fig. 8 DistributorÐ2.5L Or 4.0L EnginesÐTypical
JIGNITION SYSTEMS 8D - 19

SERVICE PROCEDURES
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG,
REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE
ATTEMPTING STEERING WHEEL COMPONENT DIAGNO-
SIS OR SERVICE. FAILURE TO TAKE PROPER PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG DE-
PLOYMENT AND POSSIBLE PERSONAL INJURY.
MULTI-FUNCTION SWITCH REMOVE/INSTALL - XJ
(1) Disconnect battery negative cable.
(2) Remove tilt lever (if equipped).
(3) Remove lower instrument panel/knee blocker
(Fig. 4).(4) Remove both upper and lower shrouds from col-
umn (Fig. 5).
(5) Remove lower fixed column shroud.
(6) Loosen steering column upper bracket nuts. Do
not remove nuts.
(7) Move upper fixed column shroud to gain access
to rear of multi-function switch (Fig. 6).
(8) Remove multi-function switch tamper proof
mounting screws (tamper proof torx bit Snap On
TTXR20B2 or equivalent required).
(9) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the connec-
tor.
(10) Remove wiring connector from multi-function
switch.
(11) Reverse removal procedures to install. Tighten
fasteners as follows:
²multi-function switch connector screw - 1.9 Nzm (17
in. lbs.)
²multi-function switch retaining screws - 1.9 Nzm
(17 in. lbs.)
²steering column upper bracket nuts - 12 Nzm(110
in. lbs.).
TURN SIGNAL/HAZARD WARNING SWITCH
REMOVE/INSTALL - YJ
(1) Disconnect battery negative cable.
(2) Remove the horn button with a push and turn
motion.
(3) Remove the horn button components (Fig. 7).
(4) Turn ignition switch to LOCK position and re-
move steering wheel nut and washer.
(5) Scribe an alignment mark on the steering in
line with the mark already existing on the end of the
steering column.
Fig. 5 Steering Column Shrouds Remove/Install
Fig. 4 Lower Instrument Panel/Knee Blocker Remove/
Install
Fig. 6 Multi-Function Switch Connector
JTURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5

LIFTGATE WIPER MOTOR REMOVE/INSTALL
(1) Remove wiper arm from motor (see Liftgate
Wiper Arm Remove/Install).
(2) Remove pivot shaft retaining nut.
(3) Remove motor trim cover (Fig. 13).
(4) Disconnect electrical connector (Fig. 14).
(5) Remove hinge nut holding motor to top.
(6) Reverse removal procedures to install.
WINDSHIELD WIPER/WASHER SWITCH
REMOVE/INSTALL
(1) Disconnect negative cable from battery.
(2) Remove horn button with a push and turn mo-
tion.
(3) Remove horn button components (Fig. 15).(4) Turn ignition switch to the LOCK position and
remove the steering wheel nut and washer.
(5) Scribe an alignment mark on the steering
wheel in line with the mark already existing on the
end of the steering column.
(6) Remove vibration damper from the steering col-
umn hub, if equipped.
(7) Remove steering wheel using a steering wheel
puller. DO NOT hammer on puller or end of steering
shaft.
WARNING: TO REMOVE THE STEERING SHAFT
SNAP RING IN THE FOLLOWING STEP, THE LOCK-
PLATE MUST BE COMPRESSED. DO NOT ATTEMPT
TO REMOVE THE LOCKPLATE WITHOUT COM-
PRESSOR TOOL C4156 AS THE LOCKPLATE IS UN-
DER HEAVY SPRING TENSION.
(8) Compress lockplate with compressor tool
C4156.
(9) Remove steering shaft snap ring (Fig. 16). Dis-
card snap ring. It is not reusable.
(10) Remove compressor tool.
(11) Remove lockplate, cancelling cam, and upper
bearing preload spring.
(12) Remove horn button components from cancel-
ing cam.
(13) Remove screw and hazard warning switch
knob.
(14) Remove dimmer switch actuator arm attach-
ing screw (Fig. 17).
(15) Remove turn/hazard switch attaching screws.
(16) Remove 6 instrument bezel screws (Fig. 18).
(17) Slide bezel toward steering wheel.
Fig. 13 Liftgate Wiper Motor Cover
Fig. 14 Liftgate Wiper Motor
Fig. 15 Steering Wheel Remove/Install
8K - 20 WIPER AND WASHER SYSTEMS - YJJ

(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

(7) Disconnect the wires at the starter motor sole-
noid and injection wire harness connector.
(8) 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. 20). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(9) Remove the fuel line bracket from the intake
manifold.
(10) Disconnect the engine ground strap.
(11) Remove the air cleaner assembly.
(12) Disconnect the vacuum purge hose at the fuel
vapor canister tee.
(13) Disconnect the idle speed actuator wire con-
nector.
(14) Disconnect the throttle cable and remove it
from the bracket.
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if
equipped.
(17) Disconnect the oxygen sensor wire connector.
(18) Disconnect the upper and lower radiator hoses
at the radiator.
(19) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(20) Disconnect the heater hoses.
(21) Remove the fan shroud screws.
(22) Remove the radiator attaching bolts.
(23) Remove the radiator and fan shroud.
(24) Remove the fan and spacer or Tempatrol fan
assembly.
(25) Install a 5/16 X 1/2-inch SAE capscrew
through fan pulley into water pump flange. This will
maintain the pulley and water pump in alignment
when crankshaft is rotated.
(26) Remove the power brake vacuum check valve
from the booster, if equipped.
(27) If equipped with power steering:(a) Disconnect the 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 objects from entering the
system.
(28) Lift the vehicle and support it with support
stands.
(29) Remove the oil filter.
(30) Remove the starter motor.
(31) Remove the flywheel housing access cover.
(32) Remove the engine support cushion-to-bracket
through bolts.
(33) Disconnect the exhaust pipe from the mani-
fold.
(34) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(35) Remove the engine shock damper bracket
from the sill.
(36) Lower the vehicle.
(37) Attach a lifting device to the engine.
(38) Raise the engine off the front supports.
(39) Place a support stand under the flywheel
housing.
(40) Remove the remaining flywheel housing bolts.
(41) Lift the engine out of the engine compartment
and install on an engine stand.
(42) 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) Insert the transmission shaft into the clutch
spline.
(4) Align the flywheel housing with the engine.
(5) Install and finger tighten the flywheel housing
lower bolts.
(6) Install the engine support cushions (if re-
moved).
(7) Remove the support stand from beneath the
flywheel housing.
(8) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten.
(9) Remove the engine lifting device.
(10) Raise the vehicle.
(11) Attach the engine shock damper bracket to
the sill.
(12) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(13) Install the flywheel housing access cover.
Fig. 20 Fuel Line Quick-Connect Couplings
J2.5L ENGINE 9 - 21

(14) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(15) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(16) Install the oil filter.
(17) Lower the vehicle.
(18) Connect the coolant hoses and tighten the
clamps.
(19) 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.
(20) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(21) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(22) Install the fan shroud and radiator.
(23) Connect the radiator hoses.
(24) Connect the heater hoses.
(25) Connect the throttle valve rod and retainer.
(26) Connect the throttle cable and install the rod.
(27) Install the throttle valve rod spring.
(28) Connect the speed control cable, if equipped.
(29) Connect the oxygen sensor wire connector.
(30) Install the vacuum hose and check valve on
the brake booster.
(31) Connect the coolant temperature sensor wire
connector.
(32) Connect the idle speed actuator wire connec-
tor.
(33) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(34) Install the fuel line bracket to the intake man-
ifold.
(35) Connect all fuel injection wire connections.
(36) Install the engine ground strap.
(37) Connect the ignition coil wire connector.
(38) Remove the coolant temperature sending unit
to permit air to escape from the block. Fill the cool-
ing system with coolant. Install the coolant tempera-
ture sending unit when the system is filled.
(39) Install the battery and connect the battery ca-
bles.
(40) Install the air cleaner bonnet to the throttle
body.
(41) Install the air cleaner.
(42) Lower the hood and secure in place.
(43) Start the engine and inspect for leaks.
(44) Stop the engine and check the fluid levels.
Add fluid, as required.ENGINE CYLINDER HEAD COVER
A cured gasket is part of the engine cylinder head
cover.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover (Fig.
1).
(3) Disconnect the fresh air inlet hose from the en-
gine cylinder head cover (Fig. 1).
(4) Remove the engine cylinder head cover mount-
ing bolts.
(5) Remove the engine cylinder head cover.
CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original dark grey gasket material should NOT
be removed. If sections of the gasket material are
missing or are compressed, replace the engine cylin-
der head cover. However, sections with minor damage
such as small cracks, cuts or chips may be repaired
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow
the gasket material to cure prior to engine cylinder
head cover installation.
INSTALLATION
(1) If a replacement cover is installed, transfer the
CCV valve grommet the oil filler cap from the origi-
nal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
Fig. 1 Engine Cylinder Head Cover
9 - 22 2.5L ENGINEJ

OIL PAN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Remove the oil pan drain plug and drain the
engine oil.
(4) Disconnect the exhaust pipe at the engine ex-
haust manifold.
(5) Disconnect the exhaust hanger at the catalytic
converter and lower the pipe.
(6) Remove the engine starter motor.
(7) Remove the flywheel/torque converter housing
access cover.
(8) Position a jack stand directly under the engine
vibration damper.
(9) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(10) Remove the engine mount through bolts.
(11) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(12) Remove the oil pan bolts. Carefully remove
the oil pan and gasket.
CLEANING
Clean the block and pan gasket surfaces.
INSTALLATION
(1) Fabricate 4 alignment dowels from 1/4ý11/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier in-
stallation and removal with a screwdriver (Fig. 1).
(2) Install two dowels in the timing case cover. Install
the other two dowels in the cylinder block (Fig. 2).
(3) Slide the one-piece gasket over the dowels and
onto the block and timing case cover.
(4) Position the oil pan over the dowels and onto
the gasket.
(5) Install the 1/4 inch oil pan bolts. Tighten these
bolts to 14 Nzm (120 in. lbs.) torque. Install the 5/16
inch oil pan bolts (Fig. 3). Tighten these bolts to 18
Nzm (156 in. lbs.) torque.
(6) Remove the dowels. Install the remaining 1/4
inch oil pan bolts. Tighten these bolts to 14 Nzm (120
in. lbs.) torque.(7) Lower the engine until it is properly located on
the engine mounts.
(8) Install the through bolts and tighten the nuts.
(9) Lower the jack stand and remove the piece of
wood.
(10) Install the flywheel and torque converter
housing access cover.
(11) Install the engine starter motor.
(12) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(13) Install the oil pan drain plug (Fig. 3). Tighten
the plug to 34 Nzm (25 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect negative cable to battery.
(16) Fill the oil pan with engine oil to the specified
level.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(17) Start the engine and inspect for leaks.
Fig. 1 Fabrication of Alignment Dowels
Fig. 2 Position of Dowels in Cylinder Block
Fig. 3 Position of 5/16 inch Oil Pan Bolts
9 - 36 2.5L ENGINEJ

(29) Disconnect the exhaust pipe from the mani-
fold.
(30) Disconnect the engine speed sensor wire con-
nection.
(31) Remove the exhaust pipe support.
(32) Remove the flywheel and converter housing
access cover.
(33)Vehicles with Automatic Transmission:
(a) Mark the converter and drive plate location.
(b) Remove the converter-to-drive plate bolts.
(34) Remove the upper flywheel and converter
housing bolts and loosen the bottom bolts.
(35) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(36) Lower the vehicle.
(37) Attach a lifting device to the engine.
(38) Raise the engine off the front supports.
(39) Place a support or floor jack under the con-
verter (or flywheel) housing.
(40) Remove the remaining converter (or flywheel)
housing bolts.
(41) Lift the engine out of the engine compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the en-
gine mount cushions from the engine mount bracket
as an aide in alignment of the engine to the trans-
mission.
(2)Vehicles with 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.
(3)Vehicles with Automatic Transmission:
(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.
(4) Install the engine mount cushions (if removed).
(5) Lower the engine and engine mount cushions
onto the engine compartment brackets. Install the
bolts and finger tighten the nuts.
(6) Remove the engine lifting device.
(7) Raise and support the vehicle.
(8) Install the remaining flywheel and converter
housing bolts. Tighten all bolts to 38 Nzm (28 ft. lbs.)
torque.
(9)Vehicles with Automatic Transmission:
(a) Install the converter-to-drive plate bolts.
(b) Ensure the installation reference marks are
aligned.
(10) Install the flywheel and converter housing ac-
cess cover.
(11) Install the exhaust pipe support and tighten
the screw.
(12) Tighten the engine mount-to-bracket bolts.
(13) Connect the engine speed sensor wire connec-
tions and tighten the screws.
(14) Connect the exhaust pipe to the manifold.
(15) Install the starter motor and connect the ca-
ble.
(16) Connect the wires to the starter motor sole-
noid.
(17) Lower the vehicle.
(18) Connect all the vacuum hoses and wire con-
nectors identified during engine removal.
(19) 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.
(20) Install the power brake vacuum check valve to
the booster, if equipped.
(21) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(22) Install the fuel line bracket to the intake man-
ifold.
(23) Connect the distributor electrical connector
and oil pressure switch connector.
(24) Connect the injection system wire harness
connector on the dash panel.
(25) Connect the line pressure cable (if equipped
with automatic transmission).
Fig. 16 Air Cleaner Assembly & Power Steering
Pump
J4.0L ENGINE 9 - 61

(18) Disconnect the oxygen sensor wire connector.
(19) Remove the upper radiator hose and coolant
recovery hose (Fig. 19).
(20) Disconnect lower radiator hoses at the radia-
tor.
(21) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(22) Remove the fan shroud screws.
(23) Remove the radiator attaching bolts.
(24) Remove the radiator and fan shroud (Fig. 19).
Refer to Group 7, Cooling System for the proper pro-
cedure.
(25) Remove the fan and spacer or Tempatrol fan
assembly.
(26) Install a 5/16 X 1/2-inch SAE capscrew
through fan pulley into water pump flange. This will
maintain the pulley and water pump in alignment
when crankshaft is rotated.
(27) Remove the power brake vacuum check valve
from the booster, if equipped.
(28) If equipped with power steering (Fig. 19):
(a) Disconnect the 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 objects from entering the
system.
(29) Lift the vehicle and support it with support
stands.
(30) Remove the starter motor.
(31) Remove the flywheel housing access cover.
(32) Remove the engine support cushion-to-bracket
through bolts.
(33) Disconnect the exhaust pipe from the mani-
fold.
(34) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(35) Lower the vehicle.
(36) Attach a lifting device to the engine.(37) Raise the engine off the front supports.
(38) Place a support stand under the flywheel
housing.
(39) Remove the remaining flywheel housing bolts.
(40) Lift the engine out of the engine compartment
and install on an engine stand.
INSTALLATION
(1) 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.
(2) Insert the transmission shaft into the clutch
spline.
(3) Align the flywheel housing with the engine.
(4) Install and finger tighten the flywheel housing
lower bolts.
(5) Install the engine support cushions (if re-
moved).
(6) Remove the support stand from beneath the
flywheel housing.
(7) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten the nuts.
(8) Remove the engine lifting device.
(9) Raise the vehicle.
(10) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(11) Install the flywheel housing access cover.
(12) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(13) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(14) Lower the vehicle.
(15) Connect the coolant hoses and tighten the
clamps.
Fig. 18 Fuel Line Quick-Connect Couplings, Air
Cleaner Assembly, Throttle & Speed Control CablesFig. 19 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Power Steering Pump
J4.0L ENGINE 9 - 63