belt JEEP CHEROKEE 1994 Service Owner's Manual

ENGINE ACCESSORY DRIVE BELTS
INDEX
page page
Automatic Belt TensionerÐXJ Models......... 36
Belt Diagnosis........................... 31
Belt Schematics......................... 34
Belt ServiceÐExcept Right Hand Drive........ 34
Belt ServiceÐWith Right Hand Drive.......... 35Belt Tension Specifications................. 34
Belt TensionÐExcept Right Hand Drive (RHD) . . 33
Belt TensionÐRight Hand Drive (RHD)........ 34
General Information....................... 31
GENERAL INFORMATION
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to water pump rotat-
ing in wrong direction. Refer to the appropriate en-
gine Belt Schematic in this group for the correct
belt routing. Or, refer to the Belt Routing Label lo-
cated in the engine compartment.
BELT DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 1), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 1). Also replace the belt if it has ex-
cessive wear, frayed cords or severe glazing.
Refer to the Serpentine Accessory Drive Belt Diag-
nosis charts for further belt diagnosis.
Fig. 1 Serpentine Belt Wear Patterns
JCOOLING SYSTEM 7 - 31

SERPENTINE DRIVE BELT DIAGNOSIS
7 - 32 COOLING SYSTEMJ

BELT TENSIONÐEXCEPT RIGHT HAND DRIVE (RHD)
Correct drive belt tension is required to ensure op-
timum performance of the belt driven engine acces-
sories. There are different types of adjustment
gauges for checking either a serpentine or a V-type
belt. Refer to the instructions supplied with thegauge. Use the correct gauge when checking belt ten-
sion. Place gauge in the middle of the section of belt
being tested (between two pulleys) to check tension
(Figs. 2, 3, 4 or 5). Do not allow the gauge (or gauge
adapter) to contact anything but the belt.
SERPENTINE DRIVE BELT DIAGNOSIS (CONT.)
Fig. 2 YJ Models with 4.0L Engine and XJ Models
with 2.5L EngineÐWith A/CFig. 3 YJ Models With 2.5L or 4.0L Engine and XJ
Models with 2.5L EngineÐWithout A/C
JCOOLING SYSTEM 7 - 33

BELT TENSIONÐRIGHT HAND DRIVE (RHD)
XJ MODELS WITH 4.0L ENGINE
It is not necessary to adjust belt tension on RHD
vehicles if equipped with a 4.0L engine. The engine
is equipped with an automatic belt tensioner (Fig. 7).
The tensioner maintains correct belt tension at all
times.Due to the use of this belt tensioner, DO
NOT attempt to use a belt tension gauge on this
engine.
BELT TENSION SPECIFICATIONS
Refer to the Specifications section at the end of this
group.
BELT SCHEMATICS
The belt routing schematics are published from the
latest information available at the time of publica-
tion.If anything differs between these schemat-
ics and the Belt Routing Label, use the
schematics on Belt Routing Label.This label is lo-
cated in the engine compartment.
Refer to figures 2, 3, 4 or 5 for proper belt routing
on vehicles with conventional left hand drive. Refer
to figure 6 for proper belt routing on vehicles with
right hand drive (RHD). Or, refer to the Belt Routing
Label located in the vehicle engine compartment.
BELT SERVICEÐEXCEPT RIGHT HAND DRIVE
The following procedures are for models equipped
with conventional left hand drive. Also refer to Belt
ServiceÐWith Right Hand Drive.
REPLACEMENT/ADJUSTMENT
Belt tension is adjusted at the power steering pump
(or idler pulley if not equipped with power steering).
To adjust belt tension or to replace belt:
(1) Loosen two rear power steering pump mounting
bolts A (Fig. 8).(2) Loosen upper pump pivot bolt B and lower lock
nut C (Fig. 9).
(3) Loosen pump adjusting bolt D (Fig. 8).
(4) If belt is to be adjusted, refer to Drive Belt Ten-
sion specifications at the end of this group for correct
tension and proceed to step 7.
If belt is to be replaced, remove belt.
(5) Check condition of all pulleys.
Fig. 4 XJ Models with 4.0L EngineÐWithout
A/CÐExcept RHD
Fig. 5 XJ Models With 4.0L EngineÐWith
A/CÐExcept RHD
Fig. 6 XJ Models With 4.0L EngineÐWith A/CÐWith
RHD
7 - 34 COOLING SYSTEMJ

CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump ro-
tating in the wrong direction. Refer to (Figs. 2, 3, 4
or 5) for correct belt routing.
(6) Install new belt. Refer to the end of this group
for Drive Belt Tension specifications.
(7) Tighten pump adjusting bolt D (Fig. 8) to at-
tain proper belt tension.(8) Tighten rear pump mounting bolts, pivot bolt
and lock nut to 27 Nzm (20 ft. lbs.) torque.
(9) After power steering pump has been tightened
into position, recheck belt tension. Adjust if neces-
sary.
BELT SERVICEÐWITH RIGHT HAND DRIVE
The following procedures are for XJ models
equipped with right hand drive (RHD) and a 4.0L en-
gine.
REMOVAL
(1) Attach a socket/wrench to the mounting bolt of
the automatic tensioner pulley (Fig. 7).
(2) Rotate the tensioner assembly clockwise (as
viewed from front) until tension has been relieved
from belt.
(3) Remove belt from idler pulley (Fig. 7) first. Re-
move belt from vehicle.
(4) Check condition and alignment of all pulleys.
INSTALLATION
(1) Position the drive belt over all pulleysexcept
the idler pulley (Fig. 7).
CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump ro-
tating in the wrong direction. Refer to (Fig. 6) for
correct engine belt routing. The correct belt with
the correct length must be used
(2) Attach a socket/wrench to the pulley mounting
bolt of the automatic tensioner (Fig. 7).
Fig. 7 Automatic Belt TensionerÐ4.0L Engine With
RHD
Fig. 8 P.S. Pump Rear Mounting BoltsÐTypical
Fig. 9 P.S. Pump Front Mounting
Bolt/LocknutÐTypical
JCOOLING SYSTEM 7 - 35

(3) Rotate the socket/wrench clockwise (Fig. 7).
Place the belt over the idler pulley. Let tensioner ro-
tate back into place. Remove wrench. Be sure belt is
properly seated in the grooves of all pulleys.
AUTOMATIC BELT TENSIONERÐXJ MODELS
4.0L ENGINE WITH RIGHT HAND DRIVE
The drive belt is equipped with a spring loaded au-
tomatic belt tensioner (Fig. 10). This belt tensioner
will be used with all belt configurations such as with
or without air conditioning.
REMOVAL
(1) Attach a socket/wrench to the mounting bolt of
the automatic tensioner pulley (Fig. 10).
(2) Rotate the tensioner assembly clockwise (as
viewed from front) until tension has been relieved
from belt.
(3) Remove belt from idler pulley (Fig. 10) first.
Remove belt from automatic tensioner.
(4) Remove tensioner mounting bolt (Fig. 10) from
tensioner bracket. Remove tensioner from vehicle.
Note alignment pin on the back of tensioner.
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(5) Remove tensioner pulley bolt. Remove pulley
from tensioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 90 Nzm (65 ft. lbs.) torque.
(2) Install tensioner assembly to mounting bracket.
An alignment pin is located on the back of tensioner.
Align this pin to the slotted hole in the mounting
bracket. Install mounting bolt and tighten to 41 Nzm
(30 ft. lbs.) torque. If automatic tensioner bracket-to-generator mounting bracket bolts were removed,
tighten to 27 Nzm (20 ft. lbs.) torque.
(3) Position the drive belt over all pulleysexcept
the idler pulley (Fig. 10).
CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump ro-
tating in the wrong direction. Refer to (Fig. 6) for
correct engine belt routing. The correct belt with
the correct length must be used
(4) Attach a socket/wrench to the pulley mounting
bolt of the automatic tensioner (Fig. 10).
(5) Rotate the socket/wrench clockwise (Fig. 10).
Place the belt over the idler pulley. Let tensioner ro-
tate back into place. Remove wrench. Be sure belt is
properly seated on all pulleys.
Fig. 10 Automatic Belt TensionerÐ4.0L Engine With
RHD
7 - 36 COOLING SYSTEMJ

SPECIFICATIONS
GENERAL INFORMATION
The following specifications are published from the
latest information available at the time of publica-
tion.If anything differs between the specifica-
tions found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compart-
ment.
DRIVE BELT TENSION
Belt tension can be adjusted only on models
equipped with conventional left hand drive. Refer to
the following Belt TensionÐExcept RHD Models
chart for specifications.
It is not necessary to adjust belt tension on right
hand drive (RHD) vehicles if equipped with a 4.0L
engine. The engine is equipped with an automatic
belt tensioner. The tensioner maintains correct belt
tension at all times.Due to the use of this belt
tensioner, DO NOT attempt to use a belt ten-
sion gauge on this engine.Refer to Automatic Belt
Tensioner for additional information.
COOLING SYSTEM CAPACITIES
BELT TENSIONÐEXCEPT RHD MODELS
7 - 38 COOLING SYSTEMJ

BATTERY TESTING GENERAL INFORMATION
Before testing a battery, clean the top of the
battery case, posts and cable terminals.
Specific gravity is a ratio of the density of the elec-
trolyte and the density of pure water. The electrolyte
is composed of sulfuric acid and water. Acid makes
up approximately 35% of the electrolyte by weight,
or 24% by volume.
The condition of a battery may be determined from
the results of 2 tests:
²hydrometer test
²ability to supply current (battery load test)
Perform the hydrometer test first. If the specific
gravity is less than 1.235, (with battery at room tem-
perature) the battery must be charged before pro-
ceeding with further testing. A battery that will not
accept a charge is defective and further testing is not
necessary.
Completely discharged batteries may take sev-
eral hours to accept a charge. See Charging
Completely Discharged Battery.
A battery that has been fully charged but does not
pass the battery load test is defective.
A battery is fully charged when:
²all cells are gassing freely during charging
²3 corrected specific gravity tests, taken at 1-hour
intervals, indicate no increase in specific gravity.
ABNORMAL BATTERY DISCHARGING
(1) Corroded battery posts and terminals.
(2) Loose or worn generator drive belt.
(3) Electrical loads that exceed the output of the
charging system due to equipment or accessories in-
stalled after delivery.
(4) Slow driving speeds (heavy traffic conditions)
or prolonged idling with high-amperage draw sys-
tems in use.
(5) Defective circuit or component causing excess
IOD. Refer to Ignition Off Draw Diagnosis in this
group.
(6) Defective charging system.
(7) Defective battery.
HYDROMETER TEST
Before performing a hydrometer test, remove
battery caps and check electrolyte level. Add
distilled water as required.
Before testing, visually inspect battery for any
damage (cracked case or cover, loose post, etc.) that
would cause the battery to be defective. To use the
hydrometer correctly, hold it with the top surface of
the electrolyte at eye level. Refer to manufacturers
instructions for correct use of hydrometer.
Remove only enough electrolyte from the battery to
keep the float off the bottom of the hydrometer bar-
rel with pressure on the bulb released. Exercise care
when inserting the tip of the hydrometer into a cellto avoid damage to the separators. Damaged separa-
tors can cause premature battery failure.
Hydrometer floats are generally calibrated to indi-
cate the specific gravity correctly only at one fixed
temperature, 80ÉF (26.6ÉC). When testing the specific
gravity at any other temperature, a correction factor
is required.
The correction factor is approximately a specific
gravity value of 0.004, referred to as 4 points of spe-
cific gravity. For each 10ÉF above 80ÉF (5.5ÉC above
26.6ÉC), add 4 points. For each 10ÉF below 80ÉF
(5.5ÉC below 26.6ÉC), subtract 4 points. Always cor-
rect the specific gravity for temperature variation.
Test the specific gravity of the electrolyte in each
battery cell.
Example: A battery is tested at 10ÉF (-12.2ÉC) and
has a specific gravity of 1.240. Determine the actual
specific gravity as follows:
²Determine the number of degrees above or below
80ÉF:
80ÉF - 10ÉF = 70ÉF
²Divide the result above by 10:
70ÉF/10 = 7
²Multiply the result from the previous step by the
temperature correction factor (0.004):
7 x 0.004 = 0.028
²The temperature at testing was below 80ÉF, there-
fore the temperature correction is subtracted:
1.240 - 0.028 = 1.212
²The corrected specific gravity is 1.212.
The fully charged battery should have a tempera-
ture corrected specific gravity of 1.260 to 1.290.
If the specific gravity of all cells is above 1.235,
and cell variation is more than 50 points (0.050), it is
an indication that the battery is unserviceable.
If the specific gravity of one or more cells is less
than 1.235, charge the battery at a rate of approxi-
mately 5 amperes. Continue charging until 3 consec-
utive specific gravity tests, taken at 1 hour intervals,
are constant.
If the cell specific gravity variation is more than 50
points (0.050) after the charge period, replace the
battery.
When the specific gravity of all cells is above 1.235
and variation between cells is less than 50 points
(0.050), the battery may be tested under heavy load.
BATTERY OPEN CIRCUIT VOLTAGE TEST
A battery voltage (no load) test will show state of
charge of a battery that will pass the Battery Load
Test described in this section.Before proceeding
with this test or Battery Load Test, completely
charge battery as described in Battery Charging
in this section.
If a battery has a no load voltage reading of 12.4
volts or greater and will not endure a load test, it is
defective and should be replaced. Refer to Group 8B -
JBATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3

(1) Connect positive lead of voltmeter to battery
negative post. Connect negative voltmeter lead to
battery negative cable clamp (Fig. 2). Rotate and
hold ignition switch in the START position. Observe
voltmeter. If voltage is detected, correct poor contact
between cable clamp and post.
(2) Connect positive lead of voltmeter to battery
positive post. Connect negative lead to battery cable
positive clamp (Fig. 2). Rotate and hold ignition
switch in the START position. Observe voltmeter. If
voltage is detected, correct poor contact between ca-
ble clamp and post.
(3) Connect a voltmeter to measure between the
battery positive post and the center of the B+ starter
solenoid stud (Fig. 3).
(4) Rotate and hold ignition switch in the START
position. If voltage reads above 0.2 volt, correct poor
STARTING SYSTEM DIAGNOSIS
TEST CONDITIONS
²PLACE GEAR SELECTOR IN PARK OR NEUTRAL AND SET PARK BRAKE OR EQUIVALENT.
²VERIFY BATTERY STATE-OF-CHARGE AND CRANKING CAPACITY, SEE BATTERY SECTION.
²CLEAN BATTERY TOP, POSTS, AND TERMINALS.
²VERIFY GENERATOR DRIVE BELT TENSION.
²DISCONNECT AND GROUND COIL CABLE.
Fig. 1 Volt-Amps Tester Connections (Typical)
8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICSJ

GENERATOR TEST PROCEDURES ON VEHICLE
INDEX
page page
Diagnostic Procedures..................... 15
General Information....................... 14Operational Check with Battery Indicator
(Base Cluster Only)..................... 14
Operational Check with Voltmeter............ 15
GENERAL INFORMATION
The generator is belt-driven by the engine. All en-
gines use serpentine drive.
The amount of DC current produced by the gener-
ator is controlled by the Powertrain Control Module
(PCM) (Fig. 1).
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD sensing systems are monitored
by the PCM. The PCM will store in electronic mem-
ory any detectable failure within the monitored cir-
cuits. Refer to Using On-Board Diagnostic System in
this group for more information.
OPERATIONAL CHECK WITH BATTERY INDICATOR
(BASE CLUSTER ONLY)
When operating normally, the indicator bulb will
come on when the ignition switch is turned to the
ON or START position. After the engine starts, the
indicator bulb goes off. With the engine running, the
charge indicator should come on only when there is a
problem in the charging system (base cluster only).
Fig. 10 Starter Motor Shimming
Fig. 1 Charging System Components (Typical)
8A - 14 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICSJ