engine JEEP XJ 1995 Service And Repair Manual

(17) Connect transmission wire harnesses and
transfer case vacuum and wire harnesses.(18) Connect transmission cooler lines.
(19) Connect transmission throttle cable at engine.
(20) Install new O-ring seal on upper half of trans-
mission fill tube. Then connect upper and lower tube
halves.
(21) Lower vehicle.
(22) Fill transmission with Mopar Dexron IIE/Mer-
con automatic transmission fluid.
Fig. 5 Transmission Mounting
Fig. 4 Installing Oil Pump Seal
21 - 200 AW-4 TRANSMISSION REMOVAL AND INSTALLATIONJ

VEHICLE VIBRATION
Vehicle vibration can be caused by:
²Tire/wheel unbalance or excessive runout
²Defective tires with extreme tread wear
²Nylon overlay flat spots (performance tires only)
²Incorrect wheel bearing adjustment (if applicable)
²Loose or worn suspension/steering components
²Certain tire tread patterns
²Incorrect drive shaft angles or excessive drive
shaft/yoke runout
²Defective or worn U-joints
²Excessive brake rotor or drum runout
²Loose engine or transmission supports/mounts
²And by engine operated accessories
Refer to the appropriate Groups in this man-
ual for additional information.
VIBRATION TYPES
There are two types of vehicle vibration:
²Mechanical
²Audible.
Mechanical vehicle vibration can be felt through
the seats, floor pan and/or steering wheel.
Audible vehicle vibration is heard above normal
background noise. The sound can be a droning or
drumming noise.
Vibrations are sensitive to change in engine torque,
vehicle speed or engine speed.
ENGINE TORQUE SENSITIVE VIBRATION
This vibration can be increased or decreased by:
²Accelerating
²Decelerating
²Coasting
²Maintaining a constant vehicle speed
VEHICLE SPEED SENSITIVE VIBRATION
This vibration condition always occurs at the same
vehicle speed regardless of the engine torque or en-
gine speed.
ENGINE SPEED (RPM) SENSITIVE VIBRATION
This vibration occurs at varying engine speeds. It
can be isolated by increasing or decreasing the en-
gine speed with the transmission in NEUTRAL posi-
tion.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a
10 mile (16 km) trip (to warm the vehicle and tires).
Then a road test to identify the vibration. Corrective
action should not be attempted until the vibration
type has been identified via a road test.
During the road test, drive the vehicle on a smooth
surface. If vibration exists, note and record the fol-
lowing information:²Identify the vehicle speed range when the vibra-
tion occurs
²Identify the type of vibration
²Identify the vibration sensitivity
²Determine if the vibration is affected by changes
in vehicle speed, engine speed and engine torque.
When the vibration has been identified, refer to the
Vibration Diagnosis chart for causes. Consider cor-
recting only those causes coded in the chart that are
related to the vibration condition.
Refer to the following cause codes and descriptions
for explanations when referring to the chart.
TRRÐTire and Wheel Radial Runout:Vehicle
speed sensitive, mechanical vibration. The runout
will not cause vibration below 20 mph (32 km/h).
WHÐWheel Hop:Vehicle speed sensitive, me-
chanical vibration. The wheel hop generates rapid
up-down movement in the steering wheel. The vibra-
tion is most noticeable in the 20 - 40 mph (32 - 64
km/h) range. The wheel hop will not cause vibration
below 20 mph (32 km/h). Wheel hop is caused by a
tire/wheel that has a radial runout of more than
0.045 of-an-inch (1.14 mm). If wheel runout is accept-
able and combined runout cannot be reduced by re-
positioning the tire on wheel, replace tire.
TBÐTire/Wheel Balance:Vehicle speed sensitive,
mechanical vibration. Static tire/wheel unbalance
will not cause vibration below 30 mph (46 km/h). Dy-
namic tire/wheel unbalance will not cause vibration
below 40 mph (64 km/h).
TLRÐTire/Wheel Lateral runout:Vehicle speed
sensitive, mechanical vibration. The runout will not
cause vibration below 50 - 55 mph (80 - 88 km/h). Ex-
cessive lateral runout will also cause front-end
shimmy.
TWÐTire Wear:Vehicle speed sensitive, audible
vibration. Abnormal tire wear causes small vibration
in the 30 - 55 mph (88 km/h) range. This will pro-
duce a whine noise at high speed. The whine will
change to a growl noise when the speed is reduced.
WÐTire Waddle:Vehicle speed sensitive, mechan-
ical vibration. Irregular tire uniformity can cause
side-to-side motion during speeds up to 15 mph (24
km/h). If the motion is excessive, identify the defec-
tive tire and replace it.
UAJÐUniversal Joint (Drive Shaft) Angles:
Torque/vehicle speed sensitive, mechanical/audible vi-
bration. Incorrect drive shaft angles cause mechani-
cal vibration below 20 mph (32 km/h) and in the 70
mph (112 km/h) range. The incorrect angles can also
produce an audible vibration in the 20 - 50 mph (32 -
80 km/h) range. Caster adjustment could be required
to correct the angles.
UJÐUniversal Joints:Engine torque/vehicle
speed sensitive, mechanical/audible vibration. If the
22 - 10 WHEELS AND TIRESJ

U-joint is worn it will cause vibration with almost
any vehicle speed/engine torque condition.
DSYÐDrive Shaft and Yokes:Vehicle speed sen-
sitive, mechanical/audible vibration. The condition
will not cause vibration below 35 mph (56 km/h). Ex-
cessive runout, unbalance or dents and bends in the
shaft will cause the vibration. Identify the actual
cause and repair/replace as necessary.
WBÐWheel Bearings:Vehicle speed sensitive,
mechanical/audible vibration. Loose wheel bearings
cause shimmy-like vibration at 35 mph (56 km/h)
and above. Worn bearings will also produce a growl
noise at low vehicle speed and a whine noise at high
vehicle speed. The wheel bearings must be adjusted
or replaced, as applicable.
ANÐAxle Noise:Engine torque/vehicle speed sen-
sitive, mechanical/audible vibration. The axle will not
cause mechanical vibration unless the axle shaft is
bent. Worn or damaged axle pinion shaft or differen-
tial gears and bearings will cause noise. Replace the
defective component(s) as necessary.
SSCÐSuspension and Steering Components:
Vehicle speed sensitive, mechanical vibration. Worn
suspension/steering components can cause mechani-
cal vibration at speeds above 20 mph (32 km/h).
Identify and repair or replace the defective compo-
nent(s).EAÐEngine Driven Accessories:Engine speed
sensitive, mechanical/audible vibration. Vibration can
be caused by loose or broken A/C compressor, PS
pump, water pump, generator or brackets, etc. Usu-
ally more noticeable when the transmission is shifted
into the NEUTRAL position and the engine speed
(rpm) increased. Inspect the engine driven accesso-
ries in the engine compartment. Repair/replace as
necessary.
ADBÐAccessory Drive Belts:Engine speed sen-
sitive, audible vibration. Worn drive belts can cause a
vibration that produces either a droning, fluttering or
rumbling noise. Inspect the drive belt(s) and tighten/
replace as necessary.
DEMÐDamaged Engine or Transmission Sup-
port Mounts:Engine speed sensitive, mechanical/
audible vibration. If a support mount is worn, noise
or vibration will occur. Inspect the support mounts
and repair/replace as necessary.
ESÐExhaust System:Engine speed sensitive,
mechanical/audible vibration. If loose exhaust compo-
nents contact the vehicle body they will cause noise
and vibration. Inspect the exhaust system for loose,
broken and mis-aligned components and repair/re-
place as necessary.
VIBRATION DIAGNOSIS
JWHEELS AND TIRES 22 - 11

RADIATOR SUPPORT CROSSMEMBERÐXJ
REMOVAL
(1) Remove the grille opening panel (GOP).
(2) For 2.5L engines, remove the power steering
pump reservoir from the left filler panel (Fig. 9).
(3) Remove the radiator support crossmember and
radiator from the front of vehicle (Fig. 10).(4) If additional disassembly is required, remove
the horns, baffle braces and the wire harnesses from
the baffles (Fig. 11).
Fig. 10 Radiator Support Crossmember & Modular Radiator
Fig. 9 P/S Pump Reservoir Removal/Installation
Fig. 11 Horns, Baffle Braces & Wire Harnesses
23 - 6 EXTERIOR COMPONENTSÐXJJ

INSTALLATION
(1) If removed, install the horns, baffle braces and
the wire harnesses on the baffles (Fig. 11).
(2) Position the radiator and the radiator support
crossmember at the front of vehicle (Fig. 10). Install
and tighten screws to 9 Nzm (76 in-lbs) torque.
(3) For 2.5L engines, install the power steering
pump reservoir on the left filler panel (Fig. 9).
(4) Install the grille opening panel (GOP).
HOODÐXJ
The hood service procedures included in this sec-
tion include:
²Hood removal and installation.
²Hood adjustment.
²HingeÐlatchÐstriker service (Fig. 12).
²Latch release cable service.
JEXTERIOR COMPONENTSÐXJ 23 - 7

(2) Install the hinge nuts on the studs. Tighten the
restraint cable nut to 4 Nzm (38 in-lbs) torque.
Tighten the remaining nuts to 9 Nzm (77 in-lbs)
torque.
If a replacement hinge seal is being installed,
position it around the hinge arm, force it
against the hinge base.
(3) Position the hinge seal around the hinge arm
and on hinge base.
(4) Install the hood.
(5) Adjust the hood as necessary.
HOOD LATCH REPLACEMENTÐXJ
REMOVAL
(1) Remove the screw that attaches the latch to the
hood inner panel (Fig. 15).
(2) Disconnect the latch from the hood and latch
connecting rod. Remove the latch from the hood.
INSTALLATION
(1) Connect the latch to the latch connecting rod
and position it on the hood inner panel.
(2) Install the screw that attaches the latch to the
hood inner panel.
(3) Tighten the screw to 9 Nzm (77 in-lbs) torque.
(4) Test the operation of the latch release cable and
latch.
HOOD LATCH STRIKER REPLACEMENTÐXJ
REMOVE
(1) Remove the grille opening panel (GOP).
(2) Remove the screws that attach the striker to
the radiator baffle (Fig. 19).
(3) Remove the striker and shims from the baffle.
INSTALLATION
(1) Position the shims and striker on the radiator
baffle and install the screws.
(2) Tighten the screws to 21 Nzm (15 ft-lbs) torque.
(3) Test the striker/hood alignment by opening and
closing the hood several times. Adjust the striker, if
necessary.
LATCH RELEASE CABLE REPLACEMENTÐXJ
REMOVAL
(1) Drill out the bellcrank to hood rivet heads and
remove the rivets (Fig. 14).
(2) Disconnect the bellcrank from the latch rod and
the latch release cable. Remove the bellcrank from
the hood.
(3) Disconnect the latch release cable from the
clips on the hood.
(4) Remove the left cowl side trim panel.
(5) Remove the cable bracket screws from the cowl
side panel.(6) Pull the cable through the dash panel and re-
move it from under the instrument panel.
INSTALLATION
(1) Insert the replacement cable end through the
hole in the dash panel into the engine compartment.
(2) Pull the cable forward and seat the grommet in
the dash panel.
(3) Position the cable bracket on the cowl side
panel and install the screws. Tighten the screws to
13 Nzm (111 in-lbs) torque.
(4) Install the left cowl side trim panel.
(5) Connect the cable and latch rod to the
bellcrank.
(6) Position the bellcrank on the hood and install
the rivets.
(7) Attach the cable to the clips.
(8) Test release the cable for proper operation.
SAFETY LATCH STRIKER REPLACEMENTÐXJ
REMOVAL
(1) Remove the striker screws from the radiator
support crossmember (Fig. 21).
(2) Remove the striker from the crossmember.
INSTALLATION
(1) Position the striker on the radiator support
crossmember and install the screws. Tighten the
screws to 9 Nzm (77 in-lbs) torque.
(2) Test the safety latch operation.
COWL WEATHERSTRIP SEAL/CROSSMEMBER AIR
DEFLECTORÐXJ
WEATHERSTRIP SEAL REPLACEMENT
(1) Pry upward along the length of seal (Fig. 22).
(2) Detach the seal retainers from the cowl panel.
(3) Remove the seal from cowl panel.
Fig. 21 Hood Safety Latch StrikerÐ2.5L Engine
(Typical)
JEXTERIOR COMPONENTSÐXJ 23 - 11

(4) Position the weatherstrip seal on the cowl panel.
Press to insert retainers into the cowl panel holes (Fig.
23).
CROSSMEMBER AIR DEFLECTOR REMOVAL
(1) Remove the rivets that attach the air deflector
to the fender flares (Fig. 22).
(2) Remove screws that attach air deflector to the
crossmember.
(3) Remove the air deflector from the crossmember.
CROSSMEMBER AIR DEFLECTOR
INSTALLATION
(1) Position the air deflector on the crossmember.
(2) Attach the air deflector to the crossmember
with the screws.
(3) Attach the air deflector to the fender flares
with blind rivets.
DASH PANEL INSULATOR PANELÐXJ
REMOVAL
(1) Remove the push-on nuts from the studs (Fig. 24).
(2) Remove the screws that attach the panel to the
dash panel.
(3) Remove the insulator panel from the dash
panel and engine compartment.
INSTALLATION
(1) Position the insulator panel on the dash panel.
(2) Install the push-on nuts on the studs.
(3) Attach the panel to the dash panel with screws.
Tighten the screws to 2 Nzm (18 in-lbs) torque.
COWL GRILLE AND SCREENÐXJ
REMOVAL
(1) Use a wax pencil to mark the position of the
wiper arms (Fig. 25).
Fig. 22 Cowl Seal and Crossmember Air Deflector
Fig. 23 Cowl Seal and Retainers
Fig. 24 Dash Panel Insulator Panel
Fig. 25 Wiper Locations On Windshield
23 - 12 EXTERIOR COMPONENTSÐXJJ

²Install the retainers to attach the fender liner to
the fender inner panel.
²Install the rivets to attach the flare to the air de-
flector (Figs. 48 and 50). and
²Install the screws to attach the flare to the fender.
Tighten the screws to 1 Nzm (13 in-lbs) torque.
(8) Connect the front lamp wire harness connectors
to the engine wire harness connectors (Fig. 52).
(9) Install the front lamps.
(10) Install the front bumper.
(11) Install the wheel, remove the support and
lower the vehicle.
(12) Right fender only: install the hood support rod
on the fender inner panel.
(13) Install the hood bumper on the fender inner
panel.(14) Right fender only: install the Daytime Run-
ning Light (DRL) module on fender inner panel.
(15) Right fender only: install the A/C Receiver/
Drier on the fender inner panel.
(16) Right fender only: install the vapor canister
on the fender inner panel. Tighten the vapor canister
screws to 5 Nzm (45 in-lbs) torque.
(17) Right fender only: install the PDC, coolant re-
covery bottle and speed servo on the fender inner
panel.
(18) Right fender only: install the hood ajar switch,
if equipped. Tighten the screws to 2 Nzm (15 in-lbs)
torque.
(19) Right fender only: install the windshield
washer fluid reservoir on the inner panel.
(20) Right fender only: install the battery tray and
battery on the inner panel.
(21) Right fender only: if equipped, install the ra-
dio antenna. Tighten the nut/escutcheon to 4.5 Nzm
(40 in-lbs) torque. Tighten the power antenna bracket
screws to 2 Nzm (20 in-lbs) torque.
REAR WHEELHOUSE FLARES AND LINERSÐXJ
REMOVAL
(1) Remove the flare and liner lower screws (Fig.
53 and 54).
(2) Remove the nuts that attach the liner to the
wheelhouse.
(3) Remove the liner from the wheelhouse.
(4) Remove the push-nuts that attach the flare re-
tainers to the wheelhouse (Fig. 55).
(5) Remove the flare and retainers from the wheel-
house.
INSTALLATION
(1) Position the flare and retainers at the wheel-
house.
(2) Install the push-nuts to attach the flare retain-
ers to the wheelhouse.
(3) Position the liner in the wheelhouse.
Fig. 50 Fender Flare & Retainers
Fig. 51 Fender Liner and Retainers
Fig. 52 Front Lamp Wire Harness Connectors
JEXTERIOR COMPONENTSÐXJ 23 - 19

TRAILER HITCH
TRAILER HITCHÐXJ
CLASS III HITCH
A class III weight-distributing/equalizer type hitch
can be used to tow a trailer:
²Having a maximum gross weight of 5,000 lbs/2250
kg.
²Having a maximum tongue weight of 750 lbs/332
kg).
The following vehicle basic equipment is required
for class III trailer towing:
²P205/75R15 or larger tires.
²Full size spare tire.
²Trailer sway control.
²Trailer tow wire harness and connector.
²Heavy duty turn signal flasher element.
²Heavy duty axle (with synthetic lubricant).
²Heavy duty cooling system.
²Heavy duty generator/battery.
²Auxiliary automatic transmission fluid cooler.
²I-6, 4.0L engine.
Wide-angle type door mirrors are recommended but
not required.
WIRE HARNESS CONNECTORS
CLASS I HITCH CONNECTOR
The trailer tow wire harness connector for class I
trailer hitches is a 5-terminal, in-line type connector.
Terminal 5 is the source for vehicle ground (Fig. 1)
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector (Fig. 2).
The 12-volt circuit for the trailer is protected
from overloads. A auto-reset type circuit
breaker is located in the trailer tow wire har-
ness near the plug-in relays.
CAUTION: The trailer tow wire harness package
does not include a vehicle battery isolator unit. Be-
cause of this, the trailer battery can totally dis-
charge the vehicle battery if the engine is not
operated for an extended period of time.
A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
Fig. 1 Trailer Tow Wire Harness Connectors
JTRAILER HITCH 23 - 77

PAINT
INTRODUCTION
Exterior vehicle body colors are identified on the
Vehicle Code plate. The plate is located on the left
side of the dash panel in the engine compartment.
The color code location is described in the Introduc-
tion of this manual. The color names provided in the
Paint and Trim Code Description chart are the color
names used on most repair product containers. The
color names in the new vehicle ordering guides may
vary depending on vehicle line but use the same color
code.
BASE COAT/CLEAR COAT FINISH
On most vehicles a two part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultra violet light and provides a dura-
ble high gloss finish.
WET SANDING,BUFFING AND POLISHING
Minor acid etching, orange peel or smudging in
clear coat can be reduced with light wet sanding,
hand buffing and polishing. If the finish has been
wet sanded in the past, it can not be repeated. Wet
sanding operation should be performed by a trained
automotive painter.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat to
shine.
PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-ble to avoid corrosion. For best results, use Mopar
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with Mopar Tar/Road Oil
Remover and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/ primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly (600 grit) wet sanded and pol-
ished with rubbing compound.
(6) On vehicles with clear coat, Apply clear top
coat to touch-up paint with the same technique as
described in step 4. Allow clear top coat to dry hard.
If desired, step 5 can be performed on clear top coat.
23 - 158 PAINTÐXJÐYJJ