Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1988-1989.1993-1995 Approved 1995 XJ Jeep Cherokee 95XJ_9
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J ENGINES 9-1
ENGINES
CONTENTS
page page
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 37 4.0L ENGINE SERVICE PROCEDURES . . . . . . . 55
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 79 ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 5
2.5L ENGINE SERVICE PROCEDURES . . . . . . . 13 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 between smooth machined metallic surfaces. It will
There are several places where form-in-place gas- not cure if left in the uncovered tube. DO NOT use
kets are used on the engine. DO NOT use form-in- on flexible metal flanges.
place gasket material unless specified. Care
must be taken when applying form-in-place gaskets. SURFACE PREPARATION
Bead size, continuity and location are of great impor- Parts assembled with form-in-place gaskets may be
tance. Too thin a bead can result in leakage while too disassembled without unusual effort. In some in-
much can result in spill-over. A continuous bead of stances, it may be necessary to lightly tap the part
the proper width is essential to obtain a leak-free with a mallet or other suitable tool to break the seal
joint. between the mating surfaces. A flat gasket scraper
Two types of form-in-place gasket materials are may also be lightly tapped into the joint but care
used in the engine area (Mopar Silicone Rubber Ad- must be taken not to damage the mating surfaces.
hesive Sealant and Mopar Gasket Maker). Each have Scrape or wire brush all gasket surfaces to remove
different properties and cannot be used interchange- all loose material. Inspect stamped parts to ensure
ably. gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
MOPAR SILICONE RUBBER ADHESIVE of oil and dirt. Make sure the old gasket material is
SEALANT removed from blind attaching holes.
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture GASKET APPLICATION
in the air causes the sealant material to cure. This Assembling parts using a form-in-place gasket re-
material is normally used on flexible metal flanges. quires care.
It has a shelf life of a year and will not properly cure Mopar Silicone Rubber Adhesive Sealant should be
if over aged. Always inspect the package for the ex- applied in a continuous bead approximately 3 mm
piration date before use. (0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
MOPAR GASKET MAKER inch) drop is placed in the center of the gasket con-
Mopar Gasket Maker, normally red in color, is tact area. Uncured sealant may be removed with a
available in 6 cc tubes. This anaerobic type gasket shop towel. Components should be torqued in place
material cures in the absence of air when squeezed while the sealant is still wet to the touch (within 10
9-2 ENGINES J
minutes). The use of a locating dowel is recom- (j) If cylinder(s) have abnormally low compres-
mended during assembly to prevent smearing the sion pressures, repeat steps 4a through 4h.
material off location. (k) If the same cylinder(s) repeat an abnormally
Mopar Gasket Maker should be applied sparingly low reading, it could indicate the existence of a
to one gasket surface. The sealant diameter should problem in the cylinder.
be 1.00 mm (0.04 inch) or less. Be certain the mate- The recommended compression pressures are
rial surrounds each mounting hole. Excess material to be used only as a guide to diagnosing engine
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 found age, primary and secondary resistance. Replace parts
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) Perform a combustion analysis.
(2) Test cranking amperage draw (refer to Group (9) Test fuel pump for pressure (refer to Group 14,
8B, Battery/Starter Service for the proper proce- Fuel System for the proper specifications).
dures). (10) Inspect air filter element (refer to Group 0,
(3) Tighten the intake manifold bolts (refer to Lubrication and Maintenance for the proper proce-
Group 11, Exhaust System and Intake Manifold for dure).
the proper specifications). (11) Inspect crankcase ventilation system (refer to
(4) Perform cylinder compression test: Group 0, Lubrication and Maintenance for the proper
(a) Check engine oil level and add oil, if neces- procedure).
sary. (12) For emission controls refer to Group 25, Emis-
(b) Drive the vehicle until engine reaches normal sion Controls System for service procedures.
operating temperature. (13) Inspect and adjust accessory belt drives (refer
(c) Select a route free from traffic and other to Group 7, Cooling System for the proper adjust-
forms of congestion, observe all traffic laws and ments).
briskly accelerate through the gears several times. (14) Road test vehicle as a final test.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres- HONING CYLINDER BORES
sion readings. Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
CAUTION: DO NOT overspeed the engine. sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
(d) Remove all spark plugs from engine. As spark C-823 equipped with 220 grit stones, is the best tool
plugs are being removed, check electrodes for ab- for this job. In addition to deglazing, it will reduce
normal firing indicators--fouled, hot, oily, etc. taper and out-of-round as well as removing light
Record cylinder number of spark plug for future scuffing, scoring or scratches. Usually a few strokes
reference. will clean up a bore and maintain the required lim-
(e) Disconnect coil wire from distributor and se- its.
cure to good ground to prevent a spark from start-
ing a fire. CAUTION: DO NOT use rigid type hones to remove
(f) Be sure throttle blades are fully open during cylinder wall glaze.
the compression check.
(g) Insert compression gage adaptor into the (2) Deglazing of the cylinder walls may be done if
No.1 spark plug hole. Crank engine until maximum the cylinder bore is straight and round. Use a cylin-
pressure is reached on gauge. Record this pressure der surfacing hone, Honing Tool C-3501, equipped
as No.1 cylinder pressure. with 280 grit stones (C-3501-3810). 20-60 strokes, de-
(h) Repeat Step 4g for all remaining cylinders. pending on the bore condition, will be sufficient to
(i) Compression should not be less than 689 kPa provide a satisfactory surface. Using honing oil
(100 psi) and not vary more than 172 kPa (25 psi) C-3501-3880 or a light honing oil available from ma-
from cylinder to cylinder. jor oil distributors.
J ENGINES 9-3
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