Cooling filter JEEP CHEROKEE 1995 Service Repair Manual

ENGINE MAINTENANCE
INDEX
page page
Accessory Drive Belt....................... 21
Air Cleaner Element....................... 18
Air-Conditioner Compressor.................. 21
Battery................................. 20
Crankcase Ventilation System................ 19
Emission Control System................... 20
Engine Break-In.......................... 15
Engine Cooling System..................... 18
Engine Oil.............................. 15Engine Oil Change and Filter Replacement...... 16
Engine Oil Filter.......................... 17
Engine Supports.......................... 21
Exhaust System.......................... 21
Fuel Filter............................... 19
Fuel Usage StatementÐGas Engines.......... 19
Ignition Cables, Distributor Cap and Rotor....... 20
Rubber and Plastic Component Inspection....... 20
Spark Plugs............................. 20
ENGINE BREAK-IN
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
After first starting a new engine, allow it to idle for
15 seconds before shifting into a drive gear. Also:
²Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
²Avoid fast acceleration and sudden stops.
²Do not drive at full-throttle for extended periods of
time.
²Do not drive at constant speeds.
²Do not idle the engine excessively.
A special break-in engine oil is not required. The
original engine oil installed is a high quality, energy
conserving lubricant. Special break-in oils are not
recommended. These oils could interfere with the
normal piston ring seating process.
New engines tend to consume more fuel and oil un-
til after the break-in period has ended.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR GOV-
ERNMENT AGENCY FOR LOCATION OF COLLEC-
TION CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied or an oil that conforms to the API Service Grade
SH or SH/CD. MOPAR provides engine oils that con-
form to all of these service grades.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity grade of engine oil. SAE 30 specifies a single
viscosity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range. Select an engine oil that is best
suited to your particular temperature range and vari-
ation (Fig.1).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommeded for
gasoline engines. They are designated as either EN-
ERGY CONSERVING or ENERGY CONSERVING
II.
Fig. 1 Temperature/Engine Oil Viscosity
JLUBRICATION AND MAINTENANCE 0 - 15

USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used en-
gine oil after it has been drained from a vehicle en-
gine. Refer to the WARNING listed above.
ENGINE COOLING SYSTEM
WARNINGS AND PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN.
DISPOSE OF GLYCOL BASE COOLANT PROP-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CENTER
IN YOUR AREA.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER-
SONAL INJURY CAN RESULT.
AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PER-
FORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures
can result.
Do not operate vehicle without proper concentra-
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal
pressure of 97 to 123 kPa (14 to 18 psi) at normal op-
erating temperature. Allow the vehicle approximately
one half hour to cool off before opening the cooling
system. As an indicator of pressure, squeeze the up-
per radiator hose between index finger and thumb. If
it collapses with little effort the system would have
low internal pressure and should be safe to open to
the first safety notch of the radiator cap. Refer to
Group 7, Cooling System.
COOLING SYSTEM INSPECTION
Coolant level should be inspected when other en-
gine compartment service is performed or when cool-
ant leak is suspected. With the engine at normal
operating temperature, observe the coolant level in
thecoolant recovery bottle. The coolant level mustbe at least above the ADD mark and preferably at
the FULL mark. Add coolant to the coolant recovery
bottleonly, if necessary.
Cooling system freeze protection should be tested
at the onset of the winter season or every 12 months.
Service is required if coolant is low, contaminated,
rusty or freeze protection is inadequate. To properly
test cooling system, see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
Ethylene Glycol based antifreeze and 50% water. Us-
ing a suitable hydrometer, measure antifreeze con-
centration in the radiator when the engine is cool. If
the cooling system has recently been serviced, allow
coolant to circulate for at least 20 minutes before
taking hydrometer reading. Properly mixed coolant
will protect the cooling system to -37ÉC (-35ÉF). If the
freeze protection is above -28ÉC (-20ÉF), drain enough
coolant from the cooling system to allow room to add
antifreeze to achieve adequate protection. A mix table
on the coolant container indicates the amount of an-
tifreeze required to winterize the cooling system
based on the capacity, see Capacity Chart in General
Information section of this group.
ANTIFREEZE SPECIFICATION
Chrysler Corporation recommends the use of Mo-
par Antifreeze/Coolant or a high quality, ethylene
glycol base antifreeze/coolant, with a silicate inhibi-
tor.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter-
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
AIR CLEANER ELEMENT
The air cleaner element should be serviced at the
intervals described in the Lubrication and Mainte-
nance Schedules sections of this group. Additional in-
formation can be found in Group 14, Fuel System
and Group 25, Emission System. Inspect all air
cleaner hoses or tubes for damage or leaks when
other engine compartment service is performed. Re-
place faulty components.
FILTER ELEMENT SERVICE/REPLACEMENT
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con-
troller to function correctly.
Do not immerse paper air filter element in clean-
ing solvents, damage can result.
(1) Remove the air cleaner cover from the body/
housing (Fig. 9).
0 - 18 LUBRICATION AND MAINTENANCEJ

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

minutes). The use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial surrounds each mounting hole. Excess material
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended during assembly to pre-
vent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label found
on the engine compartment hood.
(1) Test battery specific gravity. Add water, if nec-
essary. Clean and tighten battery connections.
(2) Test cranking amperage draw (refer to Group
8B, Battery/Starter Service for the proper proce-
dures).
(3) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
CAUTION: DO NOT overspeed the engine.
(d) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for ab-
normal firing indicatorsÐfouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maximum
pressure is reached on gauge. Record this pressure
as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 4a through 4h.
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engine
problems. An engine should NOT be disassem-
bled to determine the cause of low compression
unless some malfunction is present.
(5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(6) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
(7) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(8) Perform a combustion analysis.
(9) Test fuel pump for pressure (refer to Group 14,
Fuel System for the proper specifications).
(10) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(11) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(12) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(13) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(14) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
9 - 2 ENGINESJ

(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

(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

ASSEMBLY
Refer to the applicable sections for detailed instruc-
tions.
(1) Install the crankshaft.
(2) Install the connecting rods and the pistons
through the top of the cylinder bores.
(3) Install the front and rear oil galley plugs.
(4) Install the timing chain tensioner.
(5) Install the camshaft.
(6) Install the sprockets and chain as an assembly.
(7) Install the oil slinger to the crankshaft.
(8) Install the timing chain bumper.
(9) Install the timing case cover seal.
(10) Install the timing case cover.(11) Install the oil pan gasket and oil pan.
(12) Install the vibration damper.
(13) Install the water pump. Tighten the mounting
bolts to 31 Nzm (270 in. lbs.) torque.
(14) Remove the distributor from the cylinder
block.
(15) Lubricate the oil filter seal with clean engine
oil. Tighten oil filter to 18 Nzm (13 ft. lbs.) torque.
(16) Install the engine into the vehicle.
(17) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance).
(18) Fill the cooling system (refer to Group 7, Cool-
ing System for the proper procedures).
J2.5L ENGINE 9 - 51

²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
threads of the front and rear oil galley plugs. Tighten
the plugs to 41 Nzm (30 ft. lbs.) torque.
INSPECTIONÐCYLINDER BORE
(1) It is mandatory to use a dial bore gauge to
measure each cylinder bore diameter (Fig. 12). To
correctly select the proper size piston, a cylinder bore
gauge, Special Tool 6879, capable of reading in .00019
INCREMENTS is required. If a bore gauge is not
available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at three levels below top of bore. Start perpen-
dicular (across or at 90 degrees) to the axis of the
crankshaft and then take two additional readings.
(3) Measure the cylinder bore diameter crosswise
to the cylinder block near the top of the bore. Repeat
the measurement near the middle of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determine taper by subtracting the smaller di-
ameter from the larger diameter.
(5) Rotate measuring device 90É and repeat steps
above.
(6) Determine out-of-roundness by comparing the
difference between each measurement.
(7) If cylinder bore taper does not exceed 0.025 mm
(0.001 inch) and out-of-roundness does not exceed
0.025 mm (0.001 inch), the cylinder bore can be
honed. If the cylinder bore taper or out-of-round con-
dition exceeds these maximum limits, the cylinder
must be bored and then honed to accept an oversizepiston. A slight amount of taper always exists in the
cylinder bore after the engine has been in use for a
period of time.
HONINGÐCYLINDER BORE
The honing operation should be closely coordinated
with the fitting of pistons and rings. This will ensure
specified clearances are maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
ASSEMBLY
Refer to the applicable sections for detailed instruc-
tions.
(1) Install the crankshaft.
(2) Install the connecting rods and the pistons
through the top of the cylinder bores.
(3) Install the oil pump.
(4) Install the oil pan and gasket.
(5) Install the camshaft.
(6) Install the sprockets and chain as an assembly.
(7) Install the oil slinger from the crankshaft.
(8) Install the timing case cover seal.
(9) Install the timing case cover.
(10) Install the vibration damper.
(11) Install the water pump. Tighten the mounting
bolts to 31 Nzm (270 in. lbs.) torque.
(12) Lubricate the oil filter seal with clean engine
oil. Tighten oil filter to 18 Nzm (13 ft. lbs.) torque.
(13) Install the engine into the vehicle.
(14) Fill the engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance).
(15) Fill the cooling system (refer to Group 7, Cool-
ing System for the proper procedures).
Fig. 12 Cylinder Bore Measurement
9 - 92 4.0L ENGINEJ

CAMSHAFT POSITION SENSOR
For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
The intake manifold air temperature sensor is in-
stalled into the intake manifold plenum (Figs. 7 or
8).
REMOVAL
(1) Disconnect the electrical connector from the
sensor.
(2) Remove the sensor from the intake manifold.
INSTALLATION
(1) Install the sensor into the intake manifold.
Tighten the sensor to 28 Nzm (20 ft. lbs.) torque.
(2) Connect the electrical connector to the sensor.
CRANKSHAFT POSITION SENSOR
For description, operation and removal/installation
procedures, refer to Group 8D, Ignition Systems in
this manual.
ENGINE COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is installed in the
thermostat housing (Fig. 9).
REMOVAL
(1) Drain cooling system until the coolant level is
below the cylinder head. Observe theWARNINGSin
Group 7, Cooling.
(2) Disconnect the coolant temperature sensor wire
connector.
(3) Remove the sensor from the thermostat hous-
ing (Fig. 9).
INSTALLATION
(1) Install coolant temperature sensor into the cyl-
inder block. Tighten to 28 Nzm (21 ft. lbs.) torque.
(2) Connect the wire connector.
(3) Fill the cooling system. Refer to Group 7, Cool-
ing System.
FUEL FILTER
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL INJECTOR
REMOVAL
(1) Remove the fuel rail. Refer to Fuel Rail Re-
moval in this section.
(2) Remove the clip(s) that retain the fuel injec-
tor(s) to the fuel rail (Figs. 10 or 11).
INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as-
sembly and install retaining clip(s).
(2) If the same injector(s) is being reinstalled, in-
stall new o-ring(s).
(3) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(4) Start engine and check for fuel leaks.
Fig. 7 Sensor LocationÐ2.5L Engine
Fig. 8 Sensor LocationÐ4.0L Engine
Fig. 9 Engine Coolant Temperature SensorÐTypical
14 - 60 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATIONJ