engine JEEP CHEROKEE 1995 Service Manual Online

VISCOUS FAN DRIVE
DESCRIPTION AND OPERATION
Also refer to the previous section on Cooling Sys-
tem Fans.
The thermal viscous fan drive (Fig. 38 or 39) is a
silicone-fluid-filled coupling used to connect the fan
blades to either the engine or the water pump shaft.
The coupling allows the fan to be driven in a normal
manner. This is done at low engine speeds while lim-
iting the top speed of the fan to a predetermined
maximum level at higher engine speeds.
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit (a typical
viscous unit is shown in figure 40). This spring coil
reacts to the temperature of the radiator discharge
air. It engages the viscous fan drive for higher fan
speed if the air temperature from the radiator rises
above a certain point. Until additional engine cooling
is necessary, the fan will remain at a reduced rpm re-
gardless of engine speed.
Only when sufficient heat is present, will the vis-
cous fan drive engage. This is when the air flowing
through the radiator core causes a reaction to the bi-
metallic coil. It then increases fan speed to provide
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again re-
acts and the fan speed is reduced to the previous dis-
engaged speed.
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.CAUTION: If the viscous fan drive is replaced be-
cause of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
NOISE
It is normal for fan noise to be louder (roar-
ing) when:
²The underhood temperature is above the engage-
ment point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
²Engine loads and temperatures are high such as
when towing a trailer.
²Cool silicone fluid within the fan drive unit is be-
ing redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
TESTING
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against exces-
sively high coolant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18É-to-
105ÉC (0É-to-220É F). Insert thermometer through the
hole in the shroud. Be sure that there is adequate
clearance from the fan blades.
(3) Connect a tachometer and an engine ignition
timing light (timing light is to be used as a strobe
light).
(4) Block the air flow through the radiator. Secure
a sheet of plastic in front of the radiator (or air con-
ditioner condenser). Use tape at the top to secure the
plastic and be sure that the air flow is blocked.
Fig. 40 Typical Viscous Fan Drive
7 - 34 COOLING SYSTEM SERVICE PROCEDURESJ

(5) Be sure that the air conditioner (if equipped) is
turned off.
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.
(6) Start the engine and operate at 2400 rpm.
Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 88É C (190É F).
Fan driveengagementshould have started to occur
at between 74É to 82É C (165É to 180É F). Engage-
ment is distinguishable by a definiteincreasein fan
flow noise (roaring). The timing light also will indi-
cate an increase in the speed of the fan.
(7) When the air temperature reaches 88É C (190É
F), remove the plastic sheet. Fan drivedisengage-
mentshould have started to occur at between 57É to
79É C (135É to 175É F). A definitedecreaseof fan
flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.
VISCOUS FAN DRIVE REMOVAL/INSTALLATION
Refer to the previous section on Cooling System
Fan for removal and installation procedures of the
viscous drive unit.
Viscous Fan Drive Fluid Pump Out Require-
ment:After installing anewviscous fan drive, bring
the engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will ensure
proper fluid distribution within the drive.
AUXILIARY ELECTRIC COOLING FANÐXJ MODELS
WITH 4.0L 6-CYLINDER ENGINE
OPERATION
XJ models equipped with a 4.0L 6-cylinder engine
may also have an auxiliary electrical cooling fan.
This is with models that have air conditioning and/or
heavy duty cooling. The fan is controlled by the cool-
ing fan relay, which is located in the power distribu-
tion center (PDC). For the location of relay within
the PDC (Fig. 41), refer to the label on PDC cover.
When coolant temperature is above 88ÉC (190ÉF),
the powertrain control module (PCM) provides a
ground path for the fan relay. This ground is pro-
vided through pin/connector #31 of the PCM 60-way
connector. Battery voltage is then applied to the fan
through the relay. When coolant temperature is be-
low 88ÉC (190ÉF), the PCM opens the ground path to
the relay. This will prevent the cooling fan from be-
ing energized.
Whenever the air conditioning is operated, the
PCM engages the auxiliary cooling fan. It provides aground path to the cooling fan relay. This ground is
provided through pin/connector #31 of the PCM 60-
way connector.
DIAGNOSIS AND RELAY TESTING
The powertrain control module (PCM) will enter a
diagnostic trouble code (DTC) number 35 in memory
if it detects a problem in the auxiliary cooling fan re-
lay or circuit. This will be read as a flashing signal
at the instrument panel mounted Malfunction Indica-
tor Lamp (displayed on the instrument panel as the
CHECK ENGINE lampÐfigure 42). Refer to On-
Board Diagnostics in Group 14, Fuel Systems for in-
formation on accessing a DTC.
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
Fig. 41 PDCÐXJ Models
Fig. 42 Check Engine LampÐXJ ModelsÐTypical
JCOOLING SYSTEM SERVICE PROCEDURES 7 - 35

nostic Procedures manual for diagnostic information
and operation of the DRB scan tool.
To test operation of the fan relay only, refer to Re-
laysÐOperation/Testing. This can be found in Group
14, Fuel Systems.
REMOVAL
The auxiliary cooling fan is attached to the radia-
tor upper crossmember behind the radiator.
(1) Remove the two fan mounting bolts from radi-
ator upper crossmember (Fig. 43).
(2) Disconnect the electric fan connector.
(3) Lift fan straight up and out of vehicle.
INSTALLATION
(1) Align lower retaining tabs of fan shroud with
slots in bracket at bottom of radiator. Push fan down
into position.
(2) Tighten the mounting bolts to 4 Nzm (31 in.
lbs.) torque.
(3) Connect auxiliary cooling fan electrical connec-
tor.
TRANSMISSION OIL COOLERS
WATER-TO-OIL COOLER
All models equipped with an automatic transmis-
sion are equipped with a transmission oil cooler
mounted internally within the radiator tank. This in-
ternal cooler is supplied as standard equipment on
all models equipped with an automatic transmission.
Transmission oil is cooled when it passes through
this separate cooler. In case of a leak in the internalradiator mounted transmission oil cooler, engine cool-
ant may become mixed with transmission fluid or
transmission fluid may enter engine cooling system.
Both cooling system and transmission should be
drained and inspected if the internal radiator
mounted transmission cooler is leaking.
Also refer to the section on Transmission Air-to-Oil
Coolers. This auxiliary air-to-oil cooler is an option
on most engine packages.
REPLACING WATER-TO-OIL COOLER IN
RADIATOR SIDE TANK
The internal transmission oil cooler located within
the radiator is not serviceable. If it requires service,
the radiator must be replaced.
Once the repaired or replacement radiator has
been installed, fill the cooling system and inspect for
leaks. Refer to the Refilling Cooling System and Test-
ing Cooling System For Leaks sections in this group.
If the transmission operates properly after repairing
the leak, drain the transmission and remove the
transmission oil pan. Inspect for sludge and/or rust.
Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, the transmission and
torque convertor may not require reconditioning. Re-
fer to Group 21 for automatic transmission servicing.
AIR-TO-OIL COOLER
An auxiliary air-to-oil transmission oil cooler is
available with most engine packages.
On XJ and YJ models, the cooler is located in front
of the radiator or A/C condenser (if equipped) and be-
hind the grill (Figs. 44, 45 or 46). It is mounted to
the front frame crossmember.
Fig. 43 Auxiliary Cooling FanÐRemove/InstallÐ
Typical
Fig. 44 Auxiliary Air-To-Oil CoolerÐYJ Models
7 - 36 COOLING SYSTEM SERVICE PROCEDURESJ

The auxiliary oil coolers on all models operate in
conjunction with the internal radiator mounted main
oil cooler. The transmission oil is routed through the
main cooler first, then the auxiliary cooler, before re-
turning to the transmission.REMOVAL/INSTALLATIONÐXJ MODELS
(1) Remove the grill mounting screws and remove
the grill. Refer to Group 23, Body for procedures.
(2) Place a drain pan below the transmission oil
cooler.
(3) Remove the two hose clamps at oil cooler inlet
and outlet tubes (Figs. 45 or 46).
(4) Remove the two oil cooler mounting bolts (Figs.
45 or 46).
(5) Remove the oil cooler from vehicle.
(6) Reverse the preceding operation for installa-
tion. Tighten the two clamps 2 Nzm (15 in. lbs.)
torque. Tighten mounting bolts to 8 Nzm (72 in. lbs.)
torque.
REMOVAL/INSTALLATIONÐYJ MODELS
(1) Remove fan shroud and radiator. Refer to the
Radiators section for procedures.
(2) Remove the air conditioning filter/drier mount-
ing bolts.
WARNING: BEFORE PROCEEDING WITH THE NEXT
STEP, BE SURE TO WEAR SAFETY GLASSES. THE
A/C SYSTEM IS UNDER PRESSURE EVEN WITH
THE ENGINE OFF.
(3) Remove the A/C condenser mounting bolts (Fig.
47).
(4) Carefully tilt the A/C condenser rearward for
access to the auxiliary transmission oil cooler.
(5) Place a drain pan below the oil cooler.
(6) Remove the two hose clamps at oil cooler inlet
and outlet tubes (Fig. 44).
(7) Remove the three oil cooler mounting bolts
(Fig. 44).
(8) Remove the oil cooler from vehicle.
(9) Reverse the preceding operation for installa-
tion. Tighten the two clamps 2 Nzm (15 in. lbs.)
torque. Tighten mounting bolts to 8 Nzm (72 in. lbs.)
torque.
Fig. 45 Auxiliary Air-To-Oil CoolerÐXJ ModelsÐ4.0L
Engine
Fig. 46 Auxiliary Air-To-Oil CoolerÐXJ ModelsÐ2.5L
Engine
Fig. 47 Condenser Mounting BoltsÐYJ Models
JCOOLING SYSTEM SERVICE PROCEDURES 7 - 37

ENGINE ACCESSORY DRIVE BELTS
INDEX
page page
Automatic Belt TensionerÐXJ Models with Right
Hand Drive............................ 42
Belt Diagnosis............................ 38
Belt Schematics.......................... 38
Belt ServiceÐExcept Right Hand Drive......... 40
Belt ServiceÐXJ Models with Right Hand Drive . . . 42Belt Tension Specifications.................. 38
Belt TensionÐExcept Right Hand Drive (RHD).... 38
Belt TensionÐRight Hand Drive (RHD)......... 38
General Information....................... 38
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 Drive Belt Diagnosis charts
for further belt diagnosis.
BELT TENSIONÐEXCEPT RIGHT HAND DRIVE
(RHD)
Correct drive belt tension is required to ensure op-
timum performance of the belt driven engine accesso-
ries. There are different types of adjustment gauges
for checking either a serpentine or a V-type belt. Re-
fer to the instructions supplied with the gauge. Use
the correct gauge when checking belt tension. 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.
BELT TENSIONÐRIGHT HAND DRIVE (RHD)
XJ MODELS WITH 4.0L 6-CYLINDER ENGINE
It is not necessary to adjust belt tension on RHD
vehicles if equipped with a 4.0L 6-cylinder engine.
The engine is equipped with an automatic belt ten-
sioner (Fig. 7). The tensioner maintains correct belttension at all times.Due to the use of this belt
tensioner, DO NOT attempt to use a belt ten-
sion 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
located 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.
Fig. 1 Serpentine Belt Wear Patterns
7 - 38 ENGINE ACCESSORY DRIVE BELTSJ

SERPENTINE DRIVE BELT DIAGNOSIS
JENGINE ACCESSORY DRIVE BELTS 7 - 39

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:
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
7 - 40 ENGINE ACCESSORY DRIVE BELTSJ

(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.
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.
Fig. 4 XJ Models with 4.0L EngineÐWithout
A/CÐExcept RHD
Fig. 5 XJ Models With 4.0L EngineÐWith A/CÐ
Except RHD
Fig. 6 XJ Models With 4.0L EngineÐWith A/CÐWith
RHD
Fig. 7 Automatic Belt TensionerÐ4.0L Engine With
RHD
JENGINE ACCESSORY DRIVE BELTS 7 - 41

(9) After power steering pump has been tightened
into position, recheck belt tension. Adjust if neces-
sary.
BELT SERVICEÐXJ MODELS WITH RIGHT HAND
DRIVE
The automatic belt tensioner is used only on
XJ models equipped with a 4.0L 6-cylinder en-
gine with right hand drive steering system.
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).
(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 WITH
RIGHT HAND DRIVE
The automatic belt tensioner is used only on
XJ models equipped with a 4.0L 6-cylinder en-
gine with right hand drive steering system.
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.
Fig. 8 P.S. Pump Rear Mounting BoltsÐTypical
Fig. 9 P.S. Pump Front Mounting Bolt/LocknutÐ
Typical
7 - 42 ENGINE ACCESSORY DRIVE BELTSJ

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 6-Cylinder
Engine With RHD
JENGINE ACCESSORY DRIVE BELTS 7 - 43