battery replacement JEEP CHEROKEE 1995 Service User Guide

POWER MIRRORS
CONTENTS
page page
DIAGNOSIS............................. 1
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 4
GENERAL INFORMATION
Power outside rear view mirrors are an available
option on XJ (Cherokee) models. Following are gen-
eral descriptions of the major components in the
power mirror system. Refer to Group 8W - Wiring Di-
agrams for complete circuit descriptions and dia-
grams.
POWER MIRROR
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric mo-
tors, two drive mechanisms and the mirror glass.
One motor and drive controls mirror up-and-down
movement, and the other controls right-and-left
movement.
The mirror glass is the only serviced replacement
part for the power mirror assembly. If any other com-ponent of the mirror unit is faulty or damaged, the
entire assembly must be replaced.
POWER MIRROR SWITCH
Both the right and left mirror are controlled by a
multi-function switch located on the front of the cen-
ter console storage compartment, directly below the
armrest. The selector switch is moved right (right
mirror control), left (left mirror control), or center to
turn power mirrors off. Then one of four directional
control buttons is depressed to control movement of
the selected mirror up, down, right, or left. The
power mirror switch is serviced only as a complete
unit.
DIAGNOSIS
POWER MIRROR SYSTEM
(1) Check fuse 16 in Power Distribution Center
(PDC) and fuse 9 in fuseblock module. If OK, go to
next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse 9 in fuseblock
module. If OK, go to next step. If not OK, repair cir-
cuit to fuse 16 in PDC.
(3) Remove power mirror switch from the center
console. See Power Mirror Switch Remove/Install.
(4) Disconnect wiring harness connector from
switch. Check for battery voltage at pink wire. If OK,
go to next step. If not OK, repair circuit to fuse 9 in
fuseblock module.
(5) Check for continuity between black wire in
switch harness connector and a good ground. There
should be continuity. If OK, go to next step. If not
OK, repair circuit to ground.
(6) Check switch continuity as shown in the Mirror
Switch Continuity charts. If OK, go to next step. If
not OK, replace switch.(7) See Power Mirror Switch illustration. Connect
a jumper wire from mirror switch connector cavity
for pin E to cavity for pin F. Now connect a second
jumper from connector cavity for pin G to each of the
following pin cavities: A, B, C, then D. In each case,
the selected mirror head should move. If OK, replace
switch. If not OK, go to next step.
(8) Remove door trim panel and unplug power mir-
ror connector inside door. Connect one jumper wire to
a good ground and a second jumper wire to a battery
feed. Connect other ends of jumpers to the mirror
side of connector in door (refer to Group 8W - Wiring
Diagrams for connector cavity identification). Mirror
head should move in each of the four directions. If
OK, repair wiring between mirror switch and door
connectors. If not OK, replace mirror.
JPOWER MIRRORS 8T - 1

CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
DIAGNOSIS............................. 2
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 4
GENERAL INFORMATION
This group covers the buzzer warning system,
which is standard equipment on XJ (Cherokee)/YJ
(Wrangler) models. The system provides an audible
warning to the driver when it monitors the following
conditions:
²key is in ignition switch with the driver's door
open
²head or park lamps are on with driver's door open
(XJ only)
²driver's seat belt is not buckled with ignition
switch in ON position.
Following are general descriptions of the major
components in the buzzer warning system. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
BUZZER MODULE
The buzzer module is located in the fuseblock mod-
ule under the left end of the instrument panel. It re-
ceives battery voltage at all times from (fuse 15 - XJ,
fuse 3 - YJ) the fuseblock module. It also receives a
second battery feed (fuse 17 - XJ, fuse 9 - YJ) when
the ignition switch is in the ON or START position.
Other inputs to the module include the driver's door
jamb switch, the driver's seat belt switch, the ignition
key-in switch, and the headlamp switch (XJ only). The
only output of the module is a timed 4 to 8 second feed
to the seat belt reminder lamp in the message center of
the instrument cluster. The timer function begins after
the ignition switch is turned to the ON position.
The buzzer module can not be repaired. If faulty, it
must be replaced.
DRIVER'S DOOR JAMB SWITCH
The driver's door jamb switch is mounted to the
driver's door hinge pillar. The switch closes a path to
ground for the buzzer module through the key-in
switch or headlamp switch (XJ only) when the driv-
er's door is opened, and opens when the driver's door
is closed. This switch can not be repaired. If faulty, it
must be replaced.
IGNITION KEY-IN SWITCH
XJ MODELS
The key-in switch is integral to the ignition switch,
which is mounted on the right side of the steering col-
umn. It closes a path to ground for the buzzer module
when the ignition key is inserted in the ignition lock cyl-
inder and the driver's door jamb switch is closed (door
open). The switch opens when the key is removed from
the ignition lock cylinder. This switch can not be re-
paired. If faulty, the entire ignition switch must be re-
placed. Refer to Group 8D - Ignition Systems for service
procedures.
YJ MODELS
The key-in switch is mounted within the steering col-
umn in the lock cylinder housing. It closes a path to
ground for the buzzer module when the ignition key is
inserted in the ignition lock cylinder and the driver's
door jamb switch is closed (door open). The switch opens
when the key is removed from the ignition lock cylinder.
This switch is available for service replacement. Refer
to Group 19 - Steering for service procedures.
HEADLAMP SWITCH (XJ ONLY)
The headlamp switch is located in the instrument
panel. It closes a path to ground for the buzzer module
when the park or headlamps are on and the driver's
door jamb switch is closed (door open). The switch opens
the ground path when the park and headlamps are
turned off. The headlamp switch can not be repaired. If
faulty, it must be replaced. Refer to Group 8E - Instru-
ment Panel and Gauges for service procedures.
DRIVER'S SEAT BELT SWITCH
The driver's seat belt switch is integral to the driv-
er's seat belt buckle-half assembly. The switch is nor-
mally closed, providing a ground path to the buzzer
module. When the tip-half of the seat belt is inserted
into the seat belt buckle, the switch opens the buzzer
module ground path. The seat belt switch can not be
repaired. If faulty, the entire driver's seat belt buck-
le-half must be replaced. Refer to Group 23 - Body
Components for service procedures.
JCHIME/BUZZER WARNING SYSTEMS 8U - 1

WIRING DIAGRAMSÐGENERAL INFORMATION
INDEX
page page
Circuit Identification......................... 1
Connector and Terminal Replacement........... 7
Connector Replacement..................... 6
Connectors............................... 2
Diode Replacement........................ 8
Electrostatic Discharge (ESC) Sensitive Devices . . . 2
General Information......................... 1
Intermittent and Poor Connections.............. 4
Notes, Cautions, and Warnings................ 1Symbols................................. 2
Take Outs................................ 2
Terminal Replacement....................... 8
Terminal/Connector RepairÐMolex Connectors.... 6
Troubleshooting Tests....................... 4
Troubleshooting Tools....................... 4
Troubleshooting Wiring Problems.............. 5
Wire Code Identification..................... 1
Wiring Repair............................. 6
GENERAL INFORMATION
This Group is divided into three stand alone sec-
tions; XJ, YJ, and XJ Right Hand Drive (XJ-RHD).
Separate circuit descriptions and wiring diagrams are
provided for each vehicle. Each section contains a
Contents list for the wiring diagrams and circuit de-
scriptions for that vehicle.
The complete XJ circuit descriptions and diagrams
are printed first, followed by those for the YJ and
then the XJ-RHD. The heading at the top of each
page identifies the vehicle covered in the section.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
ALWAYS WEAR SAFETY GLASSES FOR EYE PRO-
TECTION.
USE SAFETY STANDS ANYTIME A PROCEDURE RE-
QUIRES BEING UNDER A VEHICLE.
BE SURE THAT THE IGNITION SWITCH ALWAYS IS
IN THE OFF POSITION, UNLESS THE PROCEDURE
REQUIRES IT TO BE ON.SET THE PARKING BRAKE WHEN WORKING ON
ANY VEHICLE. AN AUTOMATIC TRANSMISSION
SHOULD BE IN PARK. A MANUAL TRANSMISSION
SHOULD BE IN NEUTRAL.
OPERATE THE ENGINE ONLY IN A WELL-VENTI-
LATED AREA.
KEEP AWAY FROM MOVING PARTS WHEN THE EN-
GINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT
WITH HOT PARTS SUCH AS THE RADIATOR, EX-
HAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CON-
VERTER, AND MUFFLER.
DO NOT ALLOW FLAME OR SPARKS NEAR THE
BATTERY. GASES ARE ALWAYS PRESENT IN AND
AROUND THE BATTERY.
ALWAYS REMOVE RINGS, WATCHES, LOOSE
HANGING JEWELRY, AND LOOSE CLOTHING.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 1) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2).
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 1

WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIRÐMOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 15, and Fig. 16).
Fig. 10 Testing for Voltage DropFig. 11 Wire Repair
Fig. 12 Molex Connector Repair
8W - 6 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the re-
paired connector, if required.
(9) Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be repaired)
from its mating half/component.
(3) Cut off the existing wire connector directly be-
hind the insulator. Remove six inches of tape from the
harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 17).(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 17).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one side
of the wire. Be sure the tubing will be long enough to
cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(11) Twist the wires together (Fig. 11 example 3).
(12) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
Fig. 13 Using Special Tool 6742
Fig. 14 Connector Locking Wedge Tab (Typical)
Fig. 15 Terminal Removal
Fig. 16 Terminal Removal Using Special Tool
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 7

(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Figs. 15 and 16).
(5) Cut the wire 6 inches from the back of the
connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(12) Twist the wires together (Fig. 11 example 3).(13) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if re-
quired, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect the battery, and test all affected sys-
tems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove the
protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 18).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(8) Re-connect the battery, and test affected sys-
tems.Fig. 17 Stagger Cutting Wires (Typical)
Fig. 18 Diode Identification
8W - 8 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage, or equivalent. The
following is the recommended procedures for the use
of Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire width
of the bearing cap shell (Fig. 2). Position the Plastigage
approximately 6.35 mm (1/4 inch) off center and away
from the oil holes. In addition, suspect areas can be
checked by placing the Plastigage in the suspect area.
(3) The crankshaft must be turned until the connect-
ing rod to be checked starts moving toward the top of
the engine. Only then should the rod cap with Plasti-
gage in place be assembled. Tighten the rod cap nut to
45 Nzm (33 ft. lbs.) torque.DO NOT rotate the crank-
shaft or the Plastigage may be smeared, giving in-
accurate results.
(4) Remove the bearing cap and compare the width
of the flattened Plastigage with the scale provided on
the package (Fig. 3). Plastigage generally comes in 2
scales (one scale is in inches and the other is a met-
ric scale). Locate the band closest to the same width.
This band shows the amount of clearance. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken
(refer to Engine Specifications).
(5) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
is usually the most appropriate for checking engine
bearing clearances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole.
This brings the hole back to its original thread
size.
CAUTION: Be sure that the tapped holes maintain
the original center line.Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A service replacement engine assembly (short
block) may be installed whenever the original cylin-
der block is defective or damaged beyond repair. It
consists of the cylinder block, crankshaft, piston and
rod assemblies. If needed, the camshaft must be pro-
cured separately and installed before the engine is
installed in the vehicle.
A short block is identified with the letter ``S'' stamped
on the same machined surface where the build date
code is stamped for complete engine assemblies.
Installation includes the transfer of components
from the defective or damaged original engine. Fol-
low the appropriate procedures for cleaning, inspec-
tion and torque tightening.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Disconnect the negative cable from the battery.
(3) Inspect air cleaner, induction system and in-
take manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure in
the cylinder head. Remove the plugs from the engine.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 37 Nzm (27 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
Nzm (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil (refer to Group 0, Lubrica-
tion and Maintenance).
(15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
Fig. 3 Clearance Measurement
9 - 4 ENGINESJ

(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

at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks.
(8) Install the engine cylinder head.
VALVE TIMING
Disconnect the spark plug wires and remove the
spark plugs.
Remove the engine cylinder head cover.
Remove the capscrews, bridge and pivot assembly,
and rocker arms from above the No.1 cylinder.
Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
Rotate the crankshaft until the No.4 piston is at
top dead center (TDC) on the compression stroke.
Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90É.
Install a dial indicator on the end of the No.1 cyl-
inder intake valve push rod. Use rubber tubing to se-
cure the indicator stem on the push rod.
Set the dial indicator pointer at zero.
Rotate the crankshaft clockwise (viewed from the
front of the engine) until the dial indicator pointer
indicates 0.305 mm (0.012 inch) travel distance (lift).
The timing notch index on the vibration damper
should be aligned with the TDC mark on the timing
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
the camshaft because of pin failure. A spring pin is
available for service replacement.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt and fan
shroud.
(3) Remove the vibration damper retaining bolt
and washer.
(4) Use Vibration Damper Removal Tool 7697 to re-
move the damper from the crankshaft (Fig. 1).
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in position, align the keyway on the vi-
bration damper hub with the crankshaft key and tap
the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and
washer.
(3) Tighten the damper retaining bolt to 108 Nzm
(80 ft. lbs.) torque.
(4) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys-
tems for the proper specifications and procedures).(5) Connect negative cable to battery.
TIMING CASE COVER OIL SEAL REPLACEMENT
This procedure is done with the timing case cover
installed.
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt.
(3) Remove the vibration damper.
(4) Remove the radiator shroud.
(5) Carefully remove the oil seal. Make sure seal
bore is clean.
(6) Position the replacement oil seal on Timing
Case Cover Alignment and Seal Installation Tool
6139 with seal open end facing inward. Apply a light
film of Perfect Seal, or equivalent, on the outside di-
ameter of the seal. Lightly coat the crankshaft with
engine oil.
(7) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal In-
stallation Tool 6139 (Fig. 3). Tighten the nut against
the tool until it contacts the cover.
(8) Remove the tools. Apply a light film of engine
Fig. 1 Vibration Damper Removal Tool 7697
Fig. 3 Timing Case Cover Oil Seal Installation
9 - 30 2.5L ENGINEJ

tor in the Component Removal/Installation section of
Group 8D, Ignition Systems.
(14) Install the distributor and ignition wires. Re-
fer to Distributor in the Component Removal/Instal-
lation section of Group 8D, Ignition Systems.
(15) Install the radiator or radiator and condenser,
if equipped with A/C.
(16) Fill the cooling system.
(17) Connect negative cable to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Disconnect negative cable from battery.
(2) Drain the radiator. DO NOT waste reusable
coolant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
(4) Disconnect the radiator overflow tube, radiator
hoses, automatic transmission fluid cooler pipes (if
equipped).
(5) Remove the radiator.
(6) If equipped with air conditioning:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpentine drive
belt idler pulley.
(b) Disconnect and remove the generator.
(c) Remove the A/C condenser attaching bolts
and move the condenser and receiver/drier assem-
bly up and out of the way.
(7) Remove the serpentine drive belt.
(8) Remove the crankshaft vibration damper.
(9) Remove the timing case cover. Clean the gasket
material from the cover.
(10) Rotate crankshaft until the crankshaft
sprocket timing mark is closest to and on the center
line with the camshaft sprocket timing mark (Fig.
12).
(11) Remove camshaft sprocket retaining bolt.
(12) Remove the crankshaft oil slinger.
(13) Remove the sprockets and chain as an assem-
bly (Fig. 13).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) Inspect the damaged camshaft pin.(15) If the pin is a spring-type pin, remove the bro-
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.
(16) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: Cover the opened oil pan area to prevent
metal chips from entering the pan.
(17) Drill into the pin center witha4mm(5/32
inch) drill bit.
(18) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled, bab-
bitt-lined bearings that are pressed into the cylinder
block and then line reamed. The camshaft bearing
bores and bearing diameters are not the same size.
They are stepped down in 0.254 mm (0.010 inch) in-
crements from the front bearing (largest) to the rear
Fig. 12 Timing Chain Alignment
Fig. 13 Camshaft and Crankshaft Sprocket and
Chain
9 - 34 2.5L ENGINEJ