Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1988-1989.1993-1995 Approved 1994 XJ Jeep Cherokee 94XJ_9
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download 94XJ_9 documenatation <<
Text preview - extract from the document
J ENGINES 9 - 1
ENGINES
CONTENTS
page page
2.5L ENGINE SERVICE PROCEDURES ....... 9 ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 5
4.0L ENGINE SERVICE PROCEDURES . . . . . . 50 STANDARD SERVICE PROCEDURES . . . . . . . . . 1
STANDARD SERVICE PROCEDURES
INDEX
page page
Engine Performance . .. . . . . . . . . . . . . . . . . . . . . 2 Measuring with Plastigage . . . . . . . . . . . . . . . . . . . 3
Form-In-Place Gaskets . . . . . . . . . . . . . . . . . . . . . 1 Repair Damaged or Worn Threads . . . . . . . . . . . . 4
Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . 2 Service Engine Assembly (Short Block) . . . . . . . . . 4
Hydrostatic Lock . . . . .. . . . . . . . . . . . . . . . . . . . . 4
FORM-IN-PLACE GASKETS SURFACE PREPARATION
There are several places where form-in-place gas- Parts assembled with form-in-place gaskets may be
kets are used on the engine. DO NOT use form-in- disassembled without unusual effort. In some in-
place gasket material unless specified. Care must stances, it may be necessary to lightly tap the part
be taken when applying form-in-place gaskets. Bead with a mallet or other suitable tool to break the seal
size, continuity and location are of great importance. between the mating surfaces. A flat gasket scraper
Too thin a bead can result in leakage while too much may also be lightly tapped into the joint but care
can result in spill-over. A continuous bead of the must be taken not to damage the mating surfaces.
proper width is essential to obtain a leak-free joint. Scrape or wire brush all gasket surfaces to remove
Two types of form-in-place gasket materials are all loose material. Inspect stamped parts to ensure
used in the engine area (Mopar Silicone Rubber Ad- gasket rails are flat. Flatten rails with a hammer on
hesive Sealant and Mopar Gasket Maker). Each have a flat plate, if required. Gasket surfaces must be free
different properties and cannot be used interchange- of oil and dirt. Make sure the old gasket material is
ably. removed from blind attaching holes.
MOPAR SILICONE RUBBER ADHESIVE GASKET APPLICATION
SEALANT Assembling parts using a form-in-place gasket re-
Mopar Silicone Rubber Adhesive Sealant, normally quires care.
black in color, is available in 3 ounce tubes. Moisture Mopar Silicone Rubber Adhesive Sealant should be
in the air causes the sealant material to cure. This applied in a continuous bead approximately 3 mm
material is normally used on flexible metal flanges. (0.12 inch) in diameter. All mounting holes must be
It has a shelf life of a year and will not properly cure circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
if over aged. Always inspect the package for the ex- inch) drop is placed in the center of the gasket con-
piration date before use. tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
MOPAR GASKET MAKER while the sealant is still wet to the touch (within 10
Mopar Gasket Maker, normally red in color, is minutes). The use of a locating dowel is recom-
available in 6 cc tubes. This anaerobic type gasket mended during assembly to prevent smearing the
material cures in the absence of air when squeezed material off location.
between smooth machined metallic surfaces. It will Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
not cure if left in the uncovered tube. DO NOT use
be 1.00 mm (0.04 inch) or less. Be certain the mate-
on flexible metal flanges.
rial surrounds each mounting hole. Excess material
9 - 2 ENGINES J
can easily be wiped off. Components should be problems. An engine should NOT be disassem-
torqued in place within 15 minutes. The use of a lo- bled to determine the cause of low compression
cating dowel is recommended during assembly to pre- unless some malfunction is present.
vent smearing the material off location. (5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
ENGINE PERFORMANCE adjustment and torque).
To provide best vehicle performance and lowest ve- (6) Test resistance of spark plug cables (refer to
hicle emissions, it is most important that the tune-up Group 8D, Ignition System).
be done accurately. Use the specifications listed on (7) Inspect the primary wire. Test coil output volt-
the Vehicle Emission Control Information label age, primary and secondary resistance. Replace parts
found on the engine compartment hood. as necessary (refer to Group 8D, Ignition System and
(1) Test battery specific gravity. Add water, if nec- make necessary adjustment).
essary. Clean and tighten battery connections. (8) Set ignition timing to specifications (refer to
(2) Test cranking amperage draw (refer to Group Specification Label on engine compartment hood).
8B, Battery/Starter Service for the proper proce- (9) Perform a combustion analysis.
dures).
(10) Test fuel pump for pressure and vacuum (refer
(3) Tighten the intake manifold bolts (refer to
to Group 14, Fuel System for the proper specifica-
Group 11, Exhaust System and Intake Manifold for
tions).
the proper specifications).
(11) Inspect air filter element (refer to Group 0,
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces- Lubrication and Maintenance for the proper proce-
sary. dure).
(b) Drive the vehicle until engine reaches normal (12) Inspect crankcase ventilation system (refer to
operating temperature. Group 0, Lubrication and Maintenance for the proper
(c) Select a route free from traffic and other procedure).
forms of congestion, observe all traffic laws and (13) For emission controls refer to Group 25, Emis-
briskly accelerate through the gears several times. sion Controls System for service procedures.
The higher engine speed may help clean out valve (14) Inspect and adjust accessory belt drives (refer
seat deposits which can prevent accurate compres- to Group 7, Cooling System for the proper adjust-
sion readings. ments).
(15) Road test vehicle as a final test.
CAUTION: DO NOT overspeed the engine.
HONING CYLINDER BORES
(d) Remove all spark plugs from engine. As Before honing, stuff plenty of clean shop towels un-
spark plugs are being removed, check electrodes for der the bores and over the crankshaft to keep abra-
abnormal firing indicators - fouled, hot, oily, etc. sive materials from entering the crankshaft area.
Record cylinder number of spark plug for future (1) Used carefully, the Cylinder Bore Sizing Hone
reference. C-823 equipped with 220 grit stones, is the best tool
(e) Disconnect coil wire from distributor and se-
for this job. In addition to deglazing, it will reduce
cure to good ground to prevent a spark from start-
taper and out-of-round as well as removing light
ing a fire.
scuffing, scoring or scratches. Usually a few strokes
(f) Be sure throttle blades are fully open during
will clean up a bore and maintain the required lim-
the compression check.
its.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maxi- CAUTION: DO NOT use rigid type hones to remove
mum pressure is reached on gauge. Record this cylinder wall glaze.
pressure as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders. (2) Deglazing of the cylinder walls may be done if
(i) Compression should not be less than 689 kPa the cylinder bore is straight and round. Use a cylin-
(100 psi) and not vary more than 172 kPa (25 psi) der surfacing hone, Honing Tool C-3501, equipped
from cylinder to cylinder. with 280 grit stones (C-3501-3810). 20-60 strokes, de-
(j) If cylinder(s) have abnormally low compres- pending on the bore condition, will be sufficient to
sion pressures, repeat steps 4a through 4h. provide a satisfactory surface. Using honing oil
(k) If the same cylinder(s) repeat an abnormally C-3501-3880 or a light honing oil available from ma-
low reading, it could indicate the existence of a jor oil distributors.
problem in the cylinder.
The recommended compression pressures are CAUTION: DO NOT use engine or transmission oil,
to be used only as a guide to diagnosing engine mineral spirits or kerosene.
J ENGINES 9 - 3
(3) Honing should be done by moving the hone up ◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo