battery location JEEP YJ 1995 Service And Owner's Manual

Connector # Color Location Fig.
C239......BK ...Rear of A/C-Heater Controls.....10
C240......BK ...Rear of A/C-Heater Controls.....10
C241......BK ...Center Bottom of I.P............8
C242......GY ...Lower Left of I.P..............7
C243......BK ...Lower Left of I.P..............7
C244......GN ...Near Left Kick Panel...........7
C245......BK ...Right Rear of I.P..............8
C246......BK ...Right Rear of I.P..............8
C247......BK ...Near Left Kick Panel...........7
C248......GN ...Glove Box.................10
C249......BK ...Near Left Kick Panel...........7
C301......GY ...Behind Left Kick Panel
C302......RD ...InLeft Rear Door............13
C303......BK ...InLeft Rear Door............13
C304......BK ...InLeft Rear Door............13
C305......NAT ..InLeft Rear Door............13
C306......BK ...Near Right Seat Belt Anchor
C307......BK ...Near Floor Console
C308......BK ...Below Seat
C309......BL ...Below Right Rear Seat
C310......GN ...Below Right Rear Seat
C311......BK ...Above Fuel Tank.............19
C312......BK ...InLiftgate.................18
C313......BK ...Left Rear Quarter Panel........15
C314......BK ...Under Left Rear of Roof Liner....15
C315......BK ...InLiftgate.................18
C316......BK ...Left Rear Quarter Panel........15
C317......BK ...Left Rear Quarter Panel........15
C318......BK ...Below Right Rear Seat.........13
C319......RD ...InRight Rear Door...........13
C320......BK ...InRight Rear Door...........13
C321......BK ...InRight Rear Door...........13
C322......NAT ..InRight Rear Door...........13
C323......BK ...Right Rear Quarter Panel.......15
C324......BK ...Behind Left Kick Panel.........12
C325......BK ...Behind Left Kick Panel.........12
C326......NAT ..InFloor Console.............19
C327......BK ...Behind Dome Lamp...........11
C328......BK ...Behind Right Kick Panel........12
C329......BK ...Behind Right Kick Panel........12
C330......BK ...Behind Right Kick Panel........12
C331......BK ...Behind Right Kick Panel........12
C332......BK ...InLeft Door................12
C333......BK ...InLeft Door................12
C334......RD ...InLeft Door................12
C335......BK ...InLeft Door................12
C336......BK ...InLeft Door................12
C337......NAT ..InLeft Door................12
C338......NAT ..InRight Door...............12
C339......NAT ..InRight Door...............12
C340......BK ...InRight Door...............12
C341......BK ...InRight Door...............12
C342......RD ...InRight Door...............12
C343......BK ...InRight Door...............12
C344......BK ...InRight Door...............12Connector # Color Location Fig.
C345......BK ...Below Left Rear Seat..........14
C346......BK ...Below Left Rear Seat..........14
C347......BK ...Below Left Rear Seat..........14
C348......BK ...InLiftgate.................18
C349......BK ...InLiftgate.................18
C350......BK ...InLiftgate.................17
C351......GN ...InLiftgate.................18
C352......BK ...InLiftgate.................18
C353......BK ...Right Rear Quarter Panel.......15
C354......BK ...Right Rear Quarter Panel.......15
C355......BK ...Right Rear Quarter Panel.......15
C356......BK ...Right Rear Quarter Panel.......15
C357......BK ...Left Rear Quarter Panel
C358......BK ...Left Rear Quarter Panel........16
C359......BK ...Behind Overhead Console.......11
C401......BK ...Behind Sound Bar............15
C402......BK ...Behind Sound Bar............15
C403......BK ...Rear of Transfer Case.........20
C404......BK ...Rear of Transmission (2WD).....20
C404......BK ...Rear of Transfer Case (4WD).....20
C405......BK ...InRight Front Door
C406......BK ...InRight Front Door
C407......BK ...InFloor Console
C408......BK ...Below Floor Console..........19
C409......BK ...Behind Sound Bar............15
C410......BK ...Center of I.P.
C411......BK ...AtFuel Tank................19
C412......BK ...Behind Lens................17
C413......BK ...Behind Lens................17
C414......BK ...Behind Lens
C415......BK ...Behind Lens
C416......BK ...Behind Lens
C417......BK ...Behind Lens
C418......BK ...Behind Lens
C419......BK ...Behind Lens
C420......BK ...Behind Lens
C421......BK ...Behind Lens
C422......BK ...Right Fender Side Shield
C423......BK ...OnI.P.,Behind Lamp
G101............Left Fender Side Shield.........2
G102............Left Fender Side Shield.........2
G103............Right Rear of Engine...........4
G104............Right Rear of Engine...........4
G105............Right Rear of Engine...........4
G106............Right side of Engine, Below Ignition
Coil......................5
G107............Right side of Engine, Below Ignition
Coil......................5
G108............Right Fender Side Shield, Near Battery
.........................5
G201............Below Headlamp Switch
G301............Left Rear Quarter Panel........15
8W - 90 - 2 8W-90 CONNECTOR LOCATIONSÐXJ-RHDJ

Fig. 5 Battery and Generator Wiring
Fig. 6 Steering Column Wiring Connectors
J8W-90 CONNECTOR LOCATIONSÐXJ-RHD 8W - 90 - 7

CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-nector index is provided. Use the wiring diagrams in
each section for connector number identification. Re-
fer to the index for the proper figure number.
CONNECTOR LOCATIONS
Connector # . Color . Location Fig.
C101......BK ...RTFender Side Shield..........1
C102......BK ...RTFender Side Shield Under PDC . .1
C103......BK ...RTFender Side Shield..........1
C104......BK ...LTSide of Battery on Cowl Panel . . .1
C105 2.5L . . . NAT . . RT Rear of Engine............3
C105 4.0L . . . NAT . . RT Rear of Engine............4
C106......BK ...AtLamp...................1
C107......NAT ..Center of Cowl Panel Near
Map Sensor...............1
C108......BK ...LTKick Panel Above Park Brake . . .8
C109......BK ...Under Drivers Seat............8
C110......BK ...Under I.P.Front of Floor Tunnel....6
C111......BK ...Under I.P.Front of Floor Tunnel....6
C112......BK ...Under I.P. RT of Stop Lamp Switch .7
C113......BK ...LTFender Side Shield..........1
C114......BK ...LTSide Cowl Panel............1
C115......BK ...LTFender Side Shield..........1
C116......BK ...LTFender Side Shield..........1
C117......BK ...LTFender Side Shield..........1
C118......BK ...Bottom of Washer Reservoir......2
C119......BK ...Near Bulkhead Disconnect
2.5L only..........Not Shown
C120 2.5L . . . BK . . . Rear of Generator.............3
C120 4.0L . . . BK . . . Rear of Generator.............5
C121 2.5L . . . BK . . . RT Rear of Engine............3
C121 4.0L . . . BK . . . Rear of Generator.............4
C122......BK ...OnReceiver/Drier.............4
C123 2.5L . . . BK . . . RT Side of Engine Rear of Distributor .3
C123 4.0L . . . BK . . . RT Side of Engine Rear of Distributor .4
C124 2.5L . . . BK . . . At End of Distributor Pig Tail.....3
C124 4.0L . . . BK . . . At End of Distributor Pig Tail.....4
C125......GY ...RTSide of Transmission........5
C126......BK ...LTRear of Transmission.........5
C127......BK ...TopofFuel Tank..............9
C128......BK ...TopofRear Cross-member.......9
C129......BK ...TopofRear Cross-member.......9
C130 2.5L . . . BK . . . On Thermostat Housing.........3
C130 4.0L . . . BK . . . On Thermostat Housing.........4
C131 2.5L . . . BK . . . LT Side of Engine Bottom of Intake .3
C131 4.0L . . . BK . . . LT Side of Engine Bottom of Intake .4
C132 2.5L . . . BK . . . Injector #1.................3
C132 4.0L . . . BK . . . Injector #1.................4
C133 2.5L . . . BK . . . Injector #2.................3
C133 4.0L . . . BK . . . Injector #2.................4
C134 2.5L . . . BK . . . Injector #3.................3
C134 4.0L . . . BK . . . Injector #3.................4
C135 2.5L . . . BK . . . Injector #4.................3
C135 4.0L . . . BK . . . Injector #4.................4Connector # . Color . Location Fig.
C136......BK ...Injector #5.................4
C137......BK ...Injector #6.................4
C138 2.5L . . . BK . . . Center of Dash Panel...........1
C138 4.0L . . . BK . . . Center of Dash Panel...........1
C139......BK ...Under Bulkhead LT Side of I.P.....1
C140 2.5L . . . GY . . . LT Rear of Intake.............3
C140 4.0L . . . GY . . . LT Rear of Intake.............4
C141 2.5L . . . BK . . . Rear of Throttle Body..........3
C141 4.0L . . . BK . . . Rear of Throttle Body..........4
C142 2.5L . . . BK . . . On Throttle Body.............3
C142 4.0L . . . BK . . . On Throttle Body.............4
C143 2.5L . . . BK . . . Rear of Intake...............3
C143 4.0L . . . BK . . . Rear of Intake...............4
C144......BK ...Above Bulkhead Disconnect.......1
C145......GY ...OnPower Steering Pump........3
C146......BK ...AtHeadlamp..........Not Shown
C147......YL ...AtSide Marker Lamp..........2
C148......BK ...AtPark/Turn Lamp......Not Shown
C149......BK ...RTSide Behind Bumper.........2
C150......BK ...LTSide Behind Bumper.........2
C151......BK ...AtPark/Turn Lamp............2
C152......YL ...AtSide Marker Lamp. . . .Not Shown
C153......BK ...AtHeadlamp................2
C154......BK ...LTFender Side Shield..........2
C155......BK ...Direct Connection to Horn.......2
C156......BK ...Bottom of Washer Reservoir......2
C201......BK ...LTSide of I.P...............7
C202......BK ...OnFuse Block...............7
C203......BK ...LTKick Panel................7
C204......BK ...LTKick Panel................7
C205......BK ...LTSide Kick Panel Under I.P......7
C206......BK ...AtSpeaker...........Not Shown
C207......BK ...LTofSteering Column Rear
of Cluster.................7
C208......BK ...LTSide of Steering Column......7
C209......BK ...Rear of Switch...............7
C210......BK ...Rear of Switch...............7
C211......BK ...Base of Steering Column........7
C212......BK ...AtWiper Motor..............7
C213......BK ...RTofSteering Column Under I.P. . .7
C214......BK ...RTSide of Cluster Bezel . .Not Shown
C215......BK ...Base of Steering Column........7
C216......BK ...Base of Steering Column........7
C217......BK ...RTSide of Brake Pedal Support . . .7
C218......BK ...Base of Steering Column........7
C219......BK ...Rear of Switch...............7
C220......BK ...Rear of Switch...............7
C221......BK ...Rear of Switch...............7
J8W-90 CONNECTOR LOCATIONSÐYJ VEHICLES 8W - 90 - 1

Connector # . Color . Location Fig.
C222......BK ...Rear of Switch...............6
C223......BK ...Rear of HVAC Switch...........6
C224......BK ...Rear of Radio...............6
C225......BK ...Rear Center of I.P.............6
C226......BK ...Rear of Glove Box LT Side.......6
C227......BK ...Under I.P Right Side...........6
C228......BK ...AtSpeaker...........Not Shown
C229......BK ...RTSide of HVAC Housing.......6
C230......BK ...RTSide of HVAC Housing.......6
C231......BK ...RTKick Panel.............6,7
C232......BK ...TopofI.P.Center Support.......7
C233......BK ...TopofI.P.Center Support.......7
C301......RD ...LTKick Panel................8
C302......BK ...AtBuckle..................8
C303......BK ...LTRear Quarter Panel..........8
C304......BK ...LTRear Quarter Panel..........8
C305......BK ...RTRear Quarter Panel..........8
C306......BK ...AtMotor............Not Shown
C307......BK ...LTSide of I.P. at Lamp.........6
C308......BK ...RTSide of I.P. at Lamp.........7
C309......BK ...AtCHMSL Lamp.......Not Shown
C310......BK ...AtCHMSL Lamp.......Not Shown
C401......BK ...TopofFuel Tank..............9Connector # . Color . Location Fig.
C402......BK ...RTSide of Axle........Not Shown
C403......BK ...RTSide of Roll Bar............8
C404......GY ...LTSide Front of Transmission.....5
C405......BK ...RTSide of Transmission........5
D101............ABSDiode Under I.P.Front of
Floor Tunnel...............6
D201............Taped In Harness Near Wiper
Switch T/O................6
G101............Left of Battery on Dash Panel.....1
G102............Center of Dash Panel...........1
G103 2.5L . .......Rear of Distributor............3
G103 4.0L . .......Rear of Generator.............4
G104 2.5L . .......RTSide of Engine.............3
G104 4.0L . .......RtSide of Engine.............4
G105............RTSide Radiator Closure Panel....2
G106............LTSide Radiator Closure Panel....2
G107............RTSide of Dash Panel.........1
G108 2.5L . .......RTRear of Engine............3
G108 4.0L . .......RTRear of Engine............4
G201.............AtCigar Lighter..............6
G202.............Rear of Radio...............6
8W - 90 - 2 8W-90 CONNECTOR LOCATIONSÐYJ VEHICLESJ

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

The digits of the code identify:
(1) 1st DigitÐThe year (4 = 1994).
(2) 2nd & 3rd DigitsÐThe month (01 - 12).
(3) 4th & 5th DigitsÐThe engine type/fuel system/
compression ratio (HX = A 2.5 liter (150 CID) 9.1:1
compression ratio engine with a multi-point fuel in-
jection system).
(4) 6th & 7th DigitsÐThe day of engine build (01 -
31).
FOR EXAMPLE:Code * 401HX23 * identifies a
2.5 liter (150 CID) engine with a multi-point fuel in-
jection system, 9.1:1 compression ratio and built on
January 23, 1994.
OVERSIZE AND UNDERSIZE COMPONENT
CODES
Some engines may be built with oversize or under-
size components such as:
²Oversize cylinder bores.
²Oversize camshaft bearing bores.
²Undersize crankshaft main bearing journals.
²Undersize connecting rod journals.
These engines are identified by a letter code (Fig.
4) stamped on the oil filter boss near the distributor
(Fig. 5).
ENGINE MOUNTSÐFRONT
The front mounts support the engine at each side.
These supports are made of resilient rubber.
REMOVALÐXJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Support the engine.
(4) Remove through bolt nut (Fig. 6). DO NOT re-
move the through bolt.
(5) Remove the retaining bolts and nuts from the
support cushions (Fig. 6).
(6) Remove the through bolt.
(7) Remove the support cushions.
INSTALLATIONÐXJ VEHICLES
(1) If the engine support bracket was removed, po-
sition the LEFT bracket (Fig. 6) and the RIGHT
bracket with generator brace (Fig. 7) onto the cylin-
der block. Install the bolts and stud nuts.
(a) RIGHT SIDE (Fig. 7)ÐTighten the bolts to 61
Nzm (45 ft. lbs.) torque. Tighten the stud nuts to 46
Nzm (34 ft. lbs.) torque.
(b) LEFT SIDE (Fig. 6)ÐTighten the bolts to 61
Nzm (45 ft. lbs.) torque.
(2) If the support cushion brackets were removed,
position the brackets onto the lower front sill (Figs. 6
and 8). Install the bolts and stud nuts. Tighten the
bolts to 54 Nzm (40 ft. lbs.) torque and the stud nuts
to 41 Nzm (30 ft. lbs.) torque.
(3) Place the support cushions onto the support
cushion brackets (Fig. 6). Tighten the right support
cushion nuts to 65 Nzm (48 ft. lbs.) torque. Tighten
the left support cushion bolt and nut to 41 Nzm (30
ft. lbs.) torque.
Fig. 4 Oversize and Undersize Component Codes
Fig. 5 Oversize and Undersize Component Code
Location
9 - 14 2.5L ENGINEJ

(2) Install the upper inner retainer and bushing on
the top of the damper.
(3) Position the upper damper bracket over the
damper and install the stud nut and bolts.
(4) Tighten the stud nut to 23 Nzm (17 ft. lbs.)
torque. Tighten the bracket bolts to 61 Nzm (45 ft.
lbs.) torque.
(5) Install the bushing, upper outer retainer and
damper nut.
(6) Install the bushing, lower outer retainer and
damper nut.
(7) Tighten the upper and lower damper nuts.
(8) Connect negative cable to battery.
ENGINE ASSEMBLYÐXJ VEHICLES
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
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) Remove the lower radiator hose.
(5) Remove the upper radiator hose and coolant re-
covery hose (Fig. 15).
(6) Remove the fan shroud (Fig. 15).
(7) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(8) Remove the radiator/condenser (if equipped
with air conditioning).
(9) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and wa-
ter pump in alignment when crankshaft is rotated.
(10) Disconnect the heater hoses (Figs. 16 and 17).
(11) Disconnect the throttle linkages (Fig. 16),
speed control cable (if equipped) and throttle valve
rod.
(12) Disconnect the oxygen sensor wire connector.
(13) Disconnect the wires from the starter motor
solenoid.
(14) Disconnect all fuel injection harness connec-
tions.
(15) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 16). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove the fuel line bracket from the intake
manifold.
(17) Remove the air cleaner assembly (Fig. 18).
(18) If equipped with air conditioning, remove the
service valves and cap the compressor ports.
(19) Remove the power brake vacuum check valve
from the booster, if equipped.
(20) If equipped with power steering (Fig. 18):
Fig. 14 Engine Damper
Fig. 15 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
9 - 18 2.5L ENGINEJ

(3) Connect the CCV hoses (Fig. 1).
(4) Connect negative cable to battery.
VALVE COMPONENT REPLACEÐCYLINDER HEAD
NOT REMOVED
ROCKER ARMS AND PUSH RODS
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the capscrews at each bridge and pivot
assembly (Fig. 2). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
(3) Check for rocker arm bridges which are causing
misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensure
that the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their original position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
VALVE SPRINGS AND OIL SEALS
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer and
a set of conical valve locks. The locks can be removed
only by compressing the valve spring.
(1) Remove the engine cylinder head cover.
(2) Remove capscrews, bridge and pivot assemblies
and rocker arms for access to each valve spring to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same order
and position as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed.
(6) Install a 14 mm (1/2 inch) (thread size) air hose
adaptor in the spark plug hole.
(7) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats. For vehicles equipped with an air
conditioner, use a flexible air adaptor when servicing
the No.1 cylinder.
(8) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Fig. 2 Rocker Arm Assembly
J2.5L ENGINE 9 - 23

LEAK-DOWN TEST
After cleaning and inspection, test each tappet for
specified leak-down rate tolerance to ensure zero-lash
operation (Fig. 14).
Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Universal Leak-
Down Tester .
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di-
ameter ball bearing on the plunger cap of the tappet.
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. DO NOT tighten
the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal po-
sition.
(6) Adjust the nose of the ram to align the pointer
with the SET mark on the scale of the tester and
tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the
base of the tester clockwise one revolution every 2
seconds.
(9) Observe the leak-down time interval from the
instant the pointer aligns with the START mark on
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-
110 seconds to leak-down. Discard tappets with leak-
down time interval not within this specification.
INSTALLATION
It is not necessary to charge the tappets with en-
gine oil. They will charge themselves within a very
short period of engine operation.(1) Dip each tappet in Mopar Engine Oil Supple-
ment, or equivalent.
(2) Use Hydraulic Valve Tappet Removal/Installa-
tion Tool C-4129-A to install each tappet in the same
bore from where it was originally removed.
(3) Install the push rods in their original locations.
(4) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(5) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 Nzm (21 ft. lbs.) torque.
(6) Pour the remaining Mopar Engine Oil Supple-
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
least 1 600 km (1,000 miles). The oil supplement
need not be drained until the next scheduled oil
change.
(7) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside.
(b) Remove the air conditioner compressor
bracket bolts from the engine cylinder head.
(c) Loosen the through bolt at the bottom of the
bracket.
Fig. 14 Leak-Down Tester
J2.5L ENGINE 9 - 25

The digits of the code identify:
(1) 1st DigitÐThe year (4 = 1994).
(2) 2nd & 3rd DigitsÐThe month (01 - 12).
(3) 4th & 5th DigitsÐThe engine type/fuel system/
compression ratio (MX = A 4.0 Liter (242 CID) 8.7:1
compression ratio engine with a multi-point fuel in-
jection system).
(4) 6th & 7th DigitsÐThe day of engine build (01 -
31).
FOR EXAMPLE:Code * 401MX12 * identifies a
4.0 Liter (242 CID) engine with a multi-point fuel in-
jection system, 8.7:1 compression ratio and built on
January 12, 1994.
OVERSIZE AND UNDERSIZE COMPONENT
CODES
Some engines may be built with oversize or under-
size components such as:
²Oversize cylinder bores.
²Oversize camshaft bearing bores.
²Undersize crankshaft main bearing journals.
²Undersize connecting rod journals.
These engines are identified by a letter code (Fig.
4) stamped on a boss between the ignition coil and
the distributor (Fig. 5).
ENGINE MOUNTSÐFRONT
The front mounts support the engine at each side.
These supports are made of resilient rubber.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Support the engine.
(4) Remove the nut from the through bolt (Figs. 6
and 7). DO NOT remove the through bolt.
(5) Remove the retaining bolts and nuts from the
support cushions (Figs. 6 and 7).
(6) Remove the through bolt.
(7) Remove the support cushions.
INSTALLATION
(1) If the engine support bracket was removed, po-
sition the bracket onto the block and install the at-
taching bolts (Figs. 6 and 7). Tighten the engine
support bracket bolts:
²XJ VehiclesÐ61 Nzm (45 ft. lbs.) torque.
²YJ VehiclesÐ62 Nzm (46 ft. lbs.) torque.
(2) ON XJ VEHICLES, if the support cushion
bracket was removed, position the bracket onto the
lower front sill (Fig. 8). Install support cushion
bracket bolts and nuts. Tighten the bolts to 54 Nzm
(40 ft. lbs.) torque. Tighten the nuts to 41 Nzm (30 ft.
lbs.) torque.
(3) Place the support cushion into position on the
support cushion bracket (Figs. 6 and 7). Install and
tighten the bolts and nuts:
²XJ VehiclesÐ41 Nzm (30 ft. lbs.) torque.
²YJ VehiclesÐ52 Nzm (38 ft. lbs.) torque.
(4) Install the through bolt and the retaining nut
(Figs. 6 and 7). Tighten the through bolt nut:
²XJ VehiclesÐ65 Nzm (48 ft. lbs.) torque.
²YJ VehiclesÐ69 Nzm (51 ft. lbs.) torque.
Fig. 4 Oversize and Undersize Component Codes
Fig. 5 Oversize and Undersize Component Code
Location
9 - 56 4.0L ENGINEJ