ZJ Lube&Maintenance

7/16/2019 ZJ Lube&Maintenance

http://slidepdf.com/reader/full/zj-lubemaintenance 1/24

LUBRICATION AND MAINTENANCE

CONTENTS

page page

CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . 21DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . 11GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION

INDEX

page page

Classification of Lubricants . . . . . . . . . . . . . . . . . . . 2Components Requiring No Lubrication . . . . . . . . . . 3Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Lubrication and Replacement Parts

Recommendation . . . . . . . . . . . . . . . . . . . . . . . . 3

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2Starting Assistance (Jump Starting) . . . . . . . . . . . . 7Vehicle Lifting Recommendations . . . . . . . . . . . . . . 8Vehicle Towing Recommendations . . . . . . . . . . . . . 9

INTRODUCTIONL u br i ca t i on a n d m a i n t en a n ce i s d iv id ed i n t o r e -

quired and recommended service tasks. The required

se r vice t a sk s m u st be com p le t ed t o ver i f y e m ission

controls function correctly. The recommended service

t a s k s s h ou ld b e c om p le t ed t o m a i n t a i n s a f et y a n d

durability.Th is in for m a t ion w il l a ssist se r vice p er son n e l in

providing m aximum protection for each owner’s ve-

hicle.

C o n dit ion s ca n va r y w it h in d ivid ua l d r ivin g h a bit s .

I t i s n e ce ss a r y t o s c he du l e m a i n t en a n ce a s a t i m e

in t e rva l a s w e ll a s a d ist a n ce in t e r va l .

It is the owner’s responsibility to determine appli-

cable dr iving condition. Also t o h ave vehicle serviced

according to t he ma intenan ce schedule, a nd t o pay for

necessary parts and labor.

Veh icl es w i t h a G r os s Veh icl e Wei gh t R a t i ng

(G VWR) of 3 855 kg (8,500 lbs.) or less must conformt o l ig h t d u t y em i ss ion s t a n d a r d s . Veh i cl es w i t h a

G r o ss Ve h icle We ig h t Ra t in g (G V WR) of 3 856 k g

(8,501 lbs.) or more must conform to heavy duty emis-

sion st a n d a r d s.

The GVWR for each vehicle is listed on the Safety

Certificat ion La bel. This la bel is a ffixed to driver side

door pillar (Fig. 1).

Ad d it ion a l m a in t e n a n ce a n d lu br ica t ion in for m a -

tion is listed in the Owner’s Manual.

SEVERE DRIVING CONDITIONS

Ve h icle s su bje ct e d t o se ve r e d r ivin g con d it ion s

s h ou ld d ecr ea s e t h e i n t er v a l b et w e en com p on en tm a in t e n a n ce. S e ver e d r ivin g con d it ion s a r e d e fin ed

a s:

• F r eq u en t s h or t t r i p d r i vi n g l e ss t h a n 24 k m (15

miles)

• Frequent dr iving in dusty conditions

• Tra iler t owing

• Extensive engine idling

• Sust ained h igh speed opera tion

• Desert operation

• F r e q u en t st a r t in g a n d st op pin g

• Cold climate operation

Fig. 1 Vehicle Safety Certification Label

Z LUBRICATION AND MAINTENANCE 0 - 1



• Commercial service

When a vehicle is continuously subjected to severe

driving conditions, lubricate:

• Body components

• All driveline coupling joints

• Steering linkage

More often t ha n n ormal driving conditions

DUSTY AREAS

With this type of severe driving condition, special

care should be given t o:

• Engine a ir clean er filter

• PCV filter

• Crankcase ventilat ion system

• B rake booster control va lve air f ilter.

OFF-ROAD (4WD) OPERATION

After off-road (4WD) operat ion, ins pect underside of

vehicle. I nspect:

• Tires

• Body structure

• Steering components

• Sus pension components

• Ex h a u st sy st e m

• Threaded fasteners

HARSH SURFACE ENVIRONMENTS

After long operation in harsh environments, brake

drums, brake linings, and rear wheel bearings should

be inspected a nd cleaned.

ROUTINE MAINTENANCE

The following routine maintenance is recommendedon a monthly basis:

TIRE S—Inspect tires for unusua l wear /da ma ge.

BATTERY—Inspect and clean terminals. Determine

acid level a nd a dd dist illed wa ter, if necessar y.

F L U I D S — D e t er m in e i f com p on e n t f luid leve ls a r e

acceptable. Add fluid, if necessary.

LIG HTS/EL EC TRIC AL—Test a ll electrical syst ems

in vehicle for proper operat ion.

I t is a lso r e co m m e n d e d t h a t e n g in e o i l a n d w a sh e r

fluid level be determined at each fuel fill-up.

FUEL REQUIREM ENTSGASOLINE ENGINES

All engines require use of unleaded gasoline to re-

duce harmful effects of lead to the environment. Also

u n le a d e d f u e l is n e ce ssa r y t o p r e ve n t d a m a g e t o t h e

cat a lytic converter/O2

sensor. Fuel must have a mini-

mum octane rat ing of 87.

CAUTION: UNLEADED FUEL ONLY must be used in

vehicles equipped with a catalyst emission controlsystem. All vehicles have reminders printed on theinstrument panel below fuel gauge and on fuel filler

door. Vehicles also have fuel filler tubes that are

specially designed to accept only small-diameter

nozzles.

CLASSIFICATION OF LUBRICANTSLubricating fluids and chassis lubricants are classi-

fied a ccording t o sta nda rds r ecommended by:

• Society of Automotive Engineers (SAE)

• American P etroleum Inst itute (AP I)

• N a t io n a l L u br ica t in g G r e a se I n st i t u t e (N L G I )

ENGINE OIL (FIG. 2)

SAE VISCOSITY GRADE

An SAE viscosity grade is used to specify viscosity

of engine oil. S AE 30 specifies a single viscosity en-

gine oil.

Engine oils a lso ha ve multiple viscosit ies. These a re

specified with a dual SAE viscosity grade which indi-

cates cold-to-hot temperature viscosity range.

API SERVICE GRADE

The API Service Grade specifies the type of perfor-

mance engine oil is intended to provide. API Service

Grade specifications also apply to energy conserving

engine oils.

Conformance to API Service Grade specifications is

d e t e r m in e d by t e st s t h a t m e a su r e a bil i t y o f a n o i l t o

control:

• En g in e w e a r

• Bearing corrosion

•

Sludge• Varnish

• Oil thickening

• Rust

• P iston deposits

For maximum gasoline engine protection, use API

Service G ra de SG , S G /CD or SG /CE engine oil.

Fig. 2 SAE Oil Viscosity Grade & API Service Grade

0 - 2 LUBRICATION AND M AINTENANCE Z



GEAR LUBRICANTS

A d u a l g r a d e i s a l s o u s ed t o s peci fy v is cos it y of

multi-purpose gear lubricants.

AP I g r a d e d e sig n a t ion id en t i f ie s g e a r lu br ica n t s in

terms of recommended usa ge.

MoparS y n t h e t i c G e a r l u b e i s r e q u i r e d f o r u s e i n

vehicles with a trailer towing package.

CHASSIS COMPONENT AND WHEEL BEARING

LUBRICANTS

C h a ssis a n d w h e e l be a r in g lu br ica n t s t h a t a r e r e c-

om m e n d ed a r e id en t i f ie d by t h e N L G I C e r t i fica t ion

S y m bol. Th e sy m bol con t a in s a cod e d d e sig n a t ion .

This identifies usage and quality of the lubricant .

Th e le t t e r G w it h in t h e sy m bol d e sig n a t e s w h e el

b ea r i n g l ub r ica n t . Th e l et t e r L d es ig n a t e s ch a s s is

lu br ica n t . Wh e n t h e let t e r s a r e com bin ed , t h e lu br i-

cant can be used for dual applications.

LUBRICATION AND REPLACEMENT PARTS REC-

OMMENDATIONJ eepvehicles ar e engineered t o provide ma ny years

of dependable operation. However, lubrication service

an d m aint enance ar e required for each vehicle. When

necessary, MOPARbr a n d lu br ica n t s a n d g e n u in e r e -

pl a cem en t pa r t s a r e h ig hl y r ecom m en d ed . E a c h

MOPARbr a n d lu br ica n t a n d r e pla cem e n t p a r t is d e -

signed and to provide dependability and long service

life.

COMPONENTS REQUIRING NO LUBRICATIONTh er e a r e m a n y com pon en t s t h a t s h ou ld n ot b e

lubricated. The components that should not be lubri-

ca t e d a r e :

• Generator bearings

• B ra ke booster cylinder

• Distributors

• Drive belts• Drive belt idler pulleys

• I d ler a r m s

• Rubber bushings

• Starter motor bearings

• Suspension strut bearings

• Rear wheel bearings

• Thrott le control cables

• Throttle linkage ball joints

• Wa ter pump bear ings

Fig. 3 NLGI Lubricant Container Certification/Identification Symbol




SCHEDULED MAINTENANCE —ZJ VEHICLES (EXCEPT CALIFORNIA)

SCHEDULED MAINTENANCE —ZJ VEHICLES (EXCEPT CALIFORNIA)

0 - 4 LUBRICATION AND MAINTENANCE Z



SCHEDULED MAINTENANCE —ZJ VEHICLES (CALIFORNIA)

SCHEDULED MAINTENANCE —ZJ VEHICLES (CALIFORNIA)




GENERAL MAINTENANCE SERVICES FOR PROPER VEHICLE PERFORMANCE

GENERAL MAINTENANCE 4.0L ENGINES GENERAL MAINTENANCE 5.2L ENGINES

0 - 6 LUBRICATION AND MAINTENANCE Z



STARTING ASSISTANCE ( JUMP STARTING)

WARNING: DO NOT ATTEMPT TO PUSH OR TOW AVEHICLE TO START THE ENGINE. UNBURNED FUEL

COULD ENTER THE EXHAUST CATALYTIC CON-VERTER AND IGNITE AFTER THE ENGINE ISSTARTED. THIS COULD CAUSE THE CONVERTERTO OVERHEAT AND RUPTURE.

BOOSTER BATTERY

WARNING: TO PREVENT PERSONAL INJURY, DO

NOT ALLOW BATTERY ACID TO CONTACT EYES,SKIN OR CLOTHING. DO NOT LEAN OVER A BAT-TERY WHEN CONNECTING JUMPER CABLES. DONOT ALLOW THE POSITIVE AND NEGATIVE CABLE

CLAMPS TO CONTACT EACH OTHER. KEEP OPENFLAMES AND SPARKS AWAY FROM THE BATTERYACID VENT HOLES. ALWAYS WEAR EYE PROTEC-TION WHEN INVOLVED WITH VEHICLE BATTERIES.

If it becomes necessary to use a booster battery and

ju m p er ca ble s t o st a r t a n e n gin e, u se t h e f ol low in g

procedure.

(1) E n g a g e p a r ki n g b r a k e. S h i ft a u t om a t i c t r a n s -

m issio n t o PARK (i f a m a n u a l t r a n sm issio n , sh if t t o

NEUTRAL).

(2) Turn off a ll lights, a nd all other electrical loads.

WARNING: ACID IN A DISCHARGED BATTERY CAN

FREEZE. DO NOT ATTEMPT TO JUMP START AN

ENGINE BEFORE CHECKING CONDITION OF BAT-

TERY ACID. BATTERY COULD EXPLODE AND

CAUSE SEVERE PERSONAL INJURY.

CAUTION: Do not permit metal surfaces on vehicles

to contact. This could establish ground (negative)

continuity between vehicle bodies. This could cause

on-board computers to be damaged.

(3) At t a ch a r e d ju m p er ca ble con n e ct o r cla m p t o

posit ive (+ ) termina l on booster bat tery. Atta ch other

red cable connector clam p to posit ive (+ ) termina l on

dischar ged ba ttery (Fig. 4).

CAUTION: Do not allow positive (+) and negative (-)

cable clamps to contact each other.

WARNING: DO NOT CONNECT A JUMPER CABLE

CONNECTOR CLAMP TO NEGATIVE POST OF DIS-

CHARGED BATTERY.

(4) Connect a black jumper cable connector clam p

to n egative (-) termina l on booster bat tery. Connect

FLUID CAPACITIES




other black jumper cable connector clam p t o a good

ground source on engine tha t is to be st ar ted (Fig. 5).

Verify engine ground (negative) contact sur-

face area is free of grease. Make sure there is a

good connection to bare metal. The engine

ground (negative) connection must provide

good electrical continuity.

(5) Start engine.

WARNING: THE USE OF ANY JUMPER CABLE DIS-

CONNECTION PROCEDURE OTHER THAN THAT DE-

SCRIBED BELOW COULD RESULT IN:

• P E R S O N AL I N J U R Y C AU S E D B Y B ATTE R Y

ACID SQUIRTING FROM BATTERY VENTS

• P ERS ONAL INJ URY AND/OR P ROP ERTY DAM-

AGE CAUSED BY BATTERY EXPLOSION

• D AMAG E TO TH E B O O S TER VEH I C L E O R D I S -

AB L ED V EH I C L E C H ARG I N G S YS T EM.

(7) After engine is started, jumper cables must be

disconnected in following order:

• Black (negative) cable connector clamp from engine

ground contact

• Black (negative) cable connector clamp from nega-

tive terminal (-) on booster battery

• Red (positive) cable connector clamps from positive

(+ ) terminals on both bat teries

PORTABLE STARTING UNIT Th er e a r e m a n y t y pe s of p or t a b l e s t a r t i n g u n it s

available for start ing engines. Follow manufacturer’s

instructions.

VEHICLE LIFTING RECOMMENDATIONSRefer to Ow ner’s Manua l for emergency vehicle lift-

ing procedures.

FLOOR JACK

When properly positioned, a floor jack can be usedt o l if t a veh icle (F ig . 6). S u p por t veh icle in r a ise d

p o s i t i o n w i t h j a c k s t a n d s a t f r o n t a n d r e a r e n d s o f

f r a m e r a i ls .

CAUTION: Do not attempt to lift a vehicle with a

floor jack positioned under:

• An axle tube

Fig. 4 Positive Jumper Cable Connection

Fig. 5 Both Jumper Cables Connected On Disabled Vehicle

Fig. 6 Correct Vehicle Lifting Locations—Typical




• A body side sill

• A steering linkage component

• A drive sha ft

• The engine or t ran smission oil pa n

• The fuel tank

• A front suspension ar m

Use correct frame rail lifting locations only

(Fig. 6).

HOIST

A vehicle can be lifted wit h:

• A single-post, fra me-conta ct hoist

• A twin-post, chassis hoist

• A ra mp-type, drive-on hoist

When a frame-contact type hoist is used,verify that lifting pads are positioned properly(Fig. 6).

WARNING: WHEN A SERVICE PROCEDURE RE-QUIRES THE REMOVAL OF REAR AXLE, FUEL

TANK, OR SPARE TIRE, EITHER:

• P L AC E AD D I TI O N AL WEI G H T O N REAR E N D

O F V EH I C L E

• ATTACH VE HI CL E TO HOI ST

• P L A C E J AC K S TAN D S U N D E R VE H I C L E F O R

S U P P O RT TO P REV EN T TI P P I N G WH EN C EN TER

O F B AL AN C E C H ANG E S

4WD VEHICLES

A standard hoist can be used to lift a 4WD vehicle.

Hoist should be inspected for adequate clearance. The

lift arms, pads or ramps should be adjusted to ensure

that there is adequate clearance (Fig. 7).

Wh e n a t w in -p ost h oist is u se d , a 4 x 4 x 12-in ch

wood spacer also could be required. Place wood spacer

under front a xle. This will ma inta in bala nce and level

lifting.

CAUTION: The block that is used must be securedin a safe manner. This will ensure that it will notunbalance vehicle.

VEHICLE TOWING RECOMMENDATIONSWhen it is necessary to tow a vehicle, recommended

method is either:

• sling-type, rear-end raised towing method; or

• wheel-lift towing m ethod with a tow d olly located

under front w heels.

A vehicle with flat-bed hauling equipment can also

be used to tra nsport a disabled vehicle.

A vehicle equipped with SAE approved sling-type

t o w in g e q u ipm e n t ca n be u se d . H o w e ve r, m a n y ve-

h icles a r e e q u ip pe d w it h a ir d a m s, sp oile r s, a n d /or

ground effect panels. In this case a wheel-lift towing

vehicle or a flat-bed hauling vehicle is recommended.

If a f lat bed device is used, a pproach a ngle should not

exceed 15 degrees.

GROUND CLEARANCE

Th e l i ft e d w h e els of d isa bled veh icle sh ou ld be a

minimum of 10 cm (4 in.) off ground. Make sure there

is enough cleara nce at opposite end. This is crit ical

w h e n t o w i n g o v e r r o u g h t e r r a i n . I f r e a r w h e e l s a r e

removed, secure bra ke drum s. A 20 cm (8 in.) ground

cle a r a n ce m u st be m a in t a in e d be t w e e n br a k e d r u m s

or rotors and ground.

SAFETY PRECAUTIONS

The following safety precautions must be considered

w h e n p r ep a r in g f o r a n d d u r in g a veh icle t o w in g o p-

eration:

• Re m o ve e x h a u st p ip e t ip s t h a t in t e r f e r e w it h t o w

sling and crossbar

• P a ddin g sh ould be pla ced bet ween t ow

sling/crossbar an d an y painted surfaces

• If vehicle is da ma ged, secure loose part s

• Alw a y s u se a sa f e t y ch a in sy st e m t h a t is in d e p e n -

dent of lift ing and towing equipment

Fig. 7 Lifting 4WD Vehicle With Single-Post Hoist—Typical

Fig. 8 Tow Vehicles With Approved Equipment




• Wh e n p la cin g t o w h ook s on r e a r a x le, p osit ion

them so they do not damage brake tubing or hoses

• D o n o t a l low a n y of t ow in g e q u ip m en t t o con t a ct

f u el t a n k

• D o n o t t o w ve h icle by con n e ct in g t o f r on t or r e a r

shock absorbers

• The operator should not go under a vehicle while it

is lifted by towing equipment. The vehicle should firstbe supported by safety stands

• Do not a llow passengers in a vehicle being towed

• O bse r ve a l l s t a t e a n d loca l la w s in volvin g w a r n in g

signals, night illumina tion, speed, etc.

• Do n ot exceed a towin g s peed of 48 km/h (30 mph)

• Avoid t o w in g d ist a n ces of m or e t h a n 24 k m (15

miles) whenever possible

• D o n ot a t t a ch t ow ch a in s or a t ow s lin g t o a

bumper, steering linkage, universal joints, or a drive

sh a f t

REAR-END RAISED TOWING

I t i s r ecom m en d ed t h a t r ea r -e nd r a i s ed t ow i n g

m e t h od be u se d . Ve h icles ca n be t ow e d w it h f r on t

w h e e ls on g r ou n d f or e xt e n d ed d ist a n ces a t sp ee d s

not exceedin g 48 km/h (30 mph ).

(1) At t a ch J -h ook s a r o u n d a x le sh a f t t u bes ou t -

board of rear springs.

(2) Po sit io n a n d ce n t e r sl in g u n d e r a n d f o r w a r d o f

rear bumper.

(3) At t a ch sa f e t y ch a in s (w it h p a d s) a t e a ch e n d o f

rear bumper.

(4) Turn ignit ion switch to OFF posit ion to un lock

steering w heel.

(5) C la m p s t eer in g w h eel w i t h f ron t w h eel s i n

straight ahead posit ion.

CAUTION: Do not use steering column lock to se-

cure front wheels in straight-ahead position.

(6) Shift transmission to NEUTRAL.

FRONT-END RAISED TOWING

I f a veh icle ca n n o t be t ow e d f r om r e a r, f r on t -e n d

raised towing method normally can be used.

(1) C en t er s li n g w i t h b u mp er a n d p os it i on i t a t

frame front crossmember.

CAUTION: Use tow chains with J-hooks for connect-ing to disabled vehicle’s lower suspension arms.Never use T-hooks.

(2) Rou t e J -h ook s a n d t o w ch a in s over st e er in g

linkage outboard of coil spring.

(3) Attach J -hooks to outer end of lower suspension

a r m s .

(4) Raise vehicle.

(5) At t a ch s a f et y ch a i ns t o d is a bl ed v eh icl e a t

f r a m e r a i ls .

Vehicles equipped with a MANUAL TRANSMIS -

S I O N ca n be t o w e d w it h r e a r w h e e ls o n g r o u n d . D o

not exceed speeds of 48 km/h (30 mph) or a dista nce

of 24 km (15 miles). The transmission must be inneutral.

Front-end ra ised towing for a vehicle equipped w ith

a n AU TO MATI C TRAN S MI S S I O N is n ot r e com -

mended.

CAUTION:It is not recommended to flat tow a ve-hicle.

LOCKED VEHICLE TOWING

Wh e n a lock ed veh icle m u st be t o w e d , u se a t o w

dolly or flat bed hauler.

Fig. 9 Front-End Raised Towing—Typical




ENGINE MAINTENANCE

INDEX

page page

Air-Conditioner Compressor . . . . . . . . . . . . . . . . . 16Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 12Crankcase Ventilation System . . . . . . . . . . . . . . . 13Emr Lamp and Timer Service Information . . . . . . . 13Engine Air Cleaner Filter Element . . . . . . . . . . . . . 13Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . 11Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Engine Oil Change and Filter Replacement . . . . . . 12Exhaust Gas Recirculation (EGR) System . . . . . . . 14Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 13Ignition Cables, Distributor Cap and Rotor . . . . . . 15Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Oxygen (O2) Sensor . . . . . . . . . . . . . . . . . . . . . . . 15Rubber/Plastic Components . . . . . . . . . . . . . . . . . 15Serpentine Drive Belt . . . . . . . . . . . . . . . . . . . . . . 15Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Vacuum Operated, Emission Control

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ENGINE BREAK-INAfter first start ing a new engine, allow it to idle for

15 seconds before shifting into a drive gear. Also:

• Drive vehicle a t var ying speeds less th an 88 km/h

(55 mph) for first 480 km (300 miles).

• Avoid fa st acceleration a nd sudden st ops.

• Do not drive a t full-thrott le for extended periods of

t im e

• Do not drive at constant speeds

• Do not idle engine excessively

A special break-in engine oil is not required. The

original engine oil installed is a high quality, energy

conserving lubricant.

N ew en g in es t e n d t o con s u m e m o re f ue l a n d oi l

until a fter th e break-in period ha s ended.

ENGINE OIL

SPECIFICATIONS

API SERVICE GRADE

U s e a n en gi ne oi l t h a t con for m s t o AP I S er vi ce

G ra de S, SG /CD or SG /CE . MOPARprovides engine

oils th at conform to a ll of these service gra des.

SAE VI SCOSITY

An SAE viscosity grade is used to specify viscosity

of engine oil. S AE 30 specifies a single viscosity en-

gine oil.

Engine oils a lso have multiple viscosit ies. These a re

specified with a dual SAE viscosity grade which indi-

cates cold-to-hot temperature viscosity ra nge. Select

a n en g in e o il t h a t i s b e st s u it e d t o y ou r p a r t icu la r

temperature range and variat ion (Fig. 1).

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for

g a so lin e e n g in e s. Th e y a r e d e sig n a t e d a s e it h e r EN -

ERG Y C O N S ERV I N G o r EN ERG Y C O N S ERV I N G I I .

OIL LEVEL INDICATOR (DIPSTICK)

4.0L ENGINES 5.2L ENGINES

The engine oil level indicator is located at right rear

of engine on 4.0L engines.

The engine oil level indicator is located a t the r ight

front of the engine on 5.2L engines.

ACCEPTABLE OIL LEVEL

To main ta in proper lubrica tion of an engine, engine

oil m u st be m a in t a in e d a t a n a cce pt a ble level . Th e

acceptable level is indicated between ADD and FULL

marks on engine oil level dipstick.

The oil level should be checked periodically. The

ve h icle sh o u ld be on a leve l su r f a ce. Wa it f or f ive

m in u t es a f t e r st op pin g e n g in e o r a f t e r ve h icle h a sremained parked overnight. For 4.0 engines, add en-

gine oil only when level indicated on dipstick is at or

below ADD ma rk.

CAUTION: Do not overfill an engine crankcase with

oil.

Fig. 1 Temperature/Engine Oil Viscosity—Gasoline

Engines

Z LUBRICATION AND M AINTENANCE 0 - 11



ENGINE OIL CHANGE AND FILTER REPLACEMENT

WARNING: CARE SHOULD BE EXERCISED WHEN

CHANGING ENGINE OIL TO MINIMIZE THE LENGTH

OF EXPOSURE TIME TO USED ENGINE OIL. PRO-

TECTIVE CLOTHING AND GLOVES SHOULD BE

WORN. EXPOSED SKIN SHOULD BE THOROUGHLY

WASHED WITH SOAP AND WATER TO REMOVE

ANY USED ENGINE OIL. DO NOT USE GASOLINE,

THINNER, OR SOLVENTS TO REMOVE USED EN-

GINE OIL FROM SKIN. DO NOT POLLUTE. DISPOSE

OF USED ENGINE OIL PROPERLY. CONTACT YOUR

DEALER OR GOVERNMENT AGENCY FOR LOCA-

TION OF COLLECTION CENTER IN YOUR AREA.

ENGINE OIL FILTER

All e n g in e s a r e e q u ipp ed w it h a h ig h q u a lit y f u ll-

f low , t h r ow -a w a y t y pe oi l f il t er. Th e s a m e t y pe of

filter is recommended w hen filter is cha nged.

OIL CHANGE AND FILTER REPLACEMENT

B ring engine up to norma l operating temperature. A

more complete dra inage of oil w ill result .(1) Remove drain hole plug. Drain engine oil from

crankcase.

(2) I n st a l l d r a in h o le p lug w it h a r e pla cem e n t g a s-

ket.

For ga soline engines, oil f ilter should be replaced

during every second engine oil change.

(3) Rotate oil filter counterclockwise to remove it.

(4) Clean engine cylinder block oil filter boss.

(5) App ly a l ig h t coa t of n e w e n gin e o il t o r u bbe r

seal on oil filter.

(6) Ins ta ll a nd ha nd tight en oil filter 1/2 to 3/4 of a

turn clockwise beyond point where seal f irst contacts

cylinder block boss.

(7) Add specified q uan tity of new engine oil a t f ill

h ole loca t ion on t o p of e n gin e cy lin d e r h e a d cove r.

Wipe off any spilled oil.

(8) Observe oil level on dipstick. Adjust as neces-

sary.

(9) S t a r t en g in e. O bs er v e oi l p re ss u r e g a u g e or

warning lamp (as applicable). I f oil pressure does not

i n cr ea s e , s t op en g in e i m m ed ia t e l y a n d d et e rm i n e

cause of ma lfunction.

COOLING SYSTEM

WARNING: USE EXTREME CAUTION WHEN THE EN-

GINE IS OPERATING. DO NOT PUT YOUR HANDS

NEAR DRIVE BELT(S), PULLEYS OR FAN BLADE.

DO NOT STAND IN A DIRECT LINE WITH FAN

BLADE.

Fig. 2 Engine Oil Dipstick Location 5.2LEngine—Typical

Fig. 3 Engine Oil Dipstick—4.0L Engine

Fig. 4 Oil Filter—4.0L Engine




INSPECTION SCHEDULE

D e t e r m in e coola n t level . I n sp ect coolin g sy st e m

hoses/clamps a fter ea ch service interva l ha s elapsed.

COOLANT LEVEL

It is recommended that engine coolant level be in-

sp ect ed a t lea st on ce a m on t h d u r in g p er iod s of h ot

weather.Wi t h e ng in e a t n or m a l op er a t i n g t e mp er a t u r e,

check coolant level in coolant reserve ta nk. C oolant

l e v e l m u s t b e a t l e a s t a b o v e A D D m a r k a n d p r e f e r -

a bly a t F U L L m a r k . Ad d coola n t t o coola n t r e ser ve

ta nk only.

COOLANT FREEZE PROTECTION

C o olin g sy st e m s con t a in a 50/50 m ix t u r e of a n t i-

freeze and dist illed water. This is the recommended

coolant mixture. The factory inst alled ant i-freeze is

formulat ed t o prevent corrosion on all cooling sy stem

metal surfaces.

It is recommended t hat degree of coolan t protection

be tested every 12 months. If coolant is contaminated

or r us t y, cool in g s y st em s h ou ld b e d r a in ed a n d

flushed. Refill with a 50/50 mixture of fresh coolan t .

Refer to Group 7—Cooling Systems for addit ional in-

formation.

SYSTEM INSPECTION

WARNING: IF THE ENGINE HAS BEEN RECENTLY

OPERATED, DO NOT REMOVE RADIATOR CAP.

(1) Test ra diat or cap for proper va cuum sealing a nd

operation. Use caution when removing radiator cap to

a vo id co n t a ct w it h h o t co o la n t . Pla ce a h e a vy r a g o r

t ow e l o ver ca p a n d t u r n t o f i r st s t op . D o n ot p re ss

d ow n . P a u s e t o a l l ow p res s ur e t o r el ea s e t h r ou g h

over f low t u be. Th e n p r ess d ow n a n d t u r n cou n t e r -

clockwise to remove cap.

(2) Inspect coolant overflow tubing and connections

a t coola n t r e ser ve t a n k a n d a t r a d ia t o r.

(3) Inspect entire cooling system for leaks. A black-

l ig ht d et ect or ca n b e u s ed a s a n a i d i n d et ect in g

source of coolant leaks.

(4) Inspect ra diat or an d air conditioner condenser

fins for an accumulation of debris.(5) If necessary, refer to G roup 7—Cooling S ystems

for addit ional informa tion a nd service procedures.

RADIATOR CAP

T h e r a d ia t o r ca p m u st be co m p le t e ly t ig h t e n e d t o

provide proper pressure release and coolant recovery.

DRAIN, FLUSH AND FILL

WARNING: ANTI-FREEZE IS POISONOUS. KEEP

OUT OF REACH OF CHILDREN.

D r a in , f lu sh , a n d f i ll coolin g sy st e m w it h cor r e ct

coolant mixture at interval specified in maintenance

schedule.

HOSES AND FITTINGSIt is recommended that rubber hoses be periodically

inspected. Inspect all hose fit t ings for looseness and

cor r osion . I n sp ect r u bber h ose s f or br i t t len e ss a n dcracks.

ENGINE AIR CLEANER FILTER ELEMENT

MAINTENANCE SCHEDULE

With normal driving conditions, engine air cleaner

filter element should be replaced:

• Light-Duty Cycle—aft er each 48 000 km (30,000

miles) interval ha s elapsed

• Heavy-Dut y Cycle—aft er each 38 000 km (24,000

miles) interval ha s elapsed

When vehicle is operated in dusty areas, f ilter ele-

ment should be replaced more often.

SERVICE/REPLACEMENT

(1) Remove air cleaner cover.

(2) Remove air cleaner filter (Fig. 5).

CAUTION: Do not tap filter or immerse filter medium

in liquid to remove trapped debris.

(3) C lea n f il t e r by g en t ly blow in g t r a p p ed d e br is

from filter medium with compressed air . Direct air in

opposite direction of normal intake air f low. Keep air

nozzle at least two inches away from filter element.

(4) If f ilter medium has become partially saturated

with oil, replace filter element. Inspect crankcase ven-

tilat ing syst em for proper operat ion.

(5) Wash air cleaner cover a nd body with cleaning

solvent. Wipe it dry.

(6) Inst all a ir clean er filter element. Att ach cover to

body (Fig. 5).

EMR LAMP AND TIMER SERVICE INFORMATIONRefer to G roup 25—Emission C ontrol S ystems for

timer reset and other related information.

CRANKCASE VENTILATION SYSTEMAll J eep e n gin es a r e e q u ip pe d w it h a cr a n k ca se

ventilat ion (CCV) system. The va por is routed ba ck to

be burned in engine combustion chambers (Fig. 6).

SYSTEM OPERATION

The 4.0L engine closed crankcase ventilation (CCV)

s y s t em h a s a v a p or -t r a n s f er f it t i n g l oca t e d on t h e

cylinder head cover. A molded h ose is connected be-

t w e e n t h e in t a k e m a n if old a n d t h e f i t t in g .




RECOMMENDED MAINTENANCE

C r a n k ca s e v en t i la t i on (C C V) s y s t em s s h ou ld b e

tested, inspected and serviced at the same t ime as the

air f ilter.

Refer to G roup 25—Em ission Control Syst ems for

addit iona l serviced informa tion.

FUEL SYSTEM

INSPECTION

The fuel sy stem filler cap, nozzle, tubes, hoses, and

connections should be in spected periodically.

FUEL FILTER

Re pla ce f u e l f i lt e r a t in t e rva l sp ecif ie d in m a in t e -

nance schedule. For proper diagnosis and service pro-

cedures refer to G roup 14, Fuel S ystem.

GAS0LINE ENGINE FUEL REQUIREMENTS

All g a so lin e e n g in e s r e q u ir e f u el t h a t h a s a m in i-

m u m oct a n e r a t in g of 87 d e t e r m ine d by (R + M)/2

calculat ion method.

I n a d d i t ion , u s e o f a b r a n d of u n lea d e d g a s ol in e

t h a t con t a in s d e t er g en t , cor r osion a n d st a bil it y a d d i-

t ives is r e com m e n d ed . G a solin e w it h t h e se t y p e o f

ad dit ives w ill improve fuel economy a nd reduce emis-sions.

ALCOHOL/GASOLINE BLENDS

Many brands of blended unleaded gasoline are now

available. This type of blended fuel is sometimes re-

ferred t o as reformulat ed ga soline.

Unleaded gasoline is blended with oxygenated-type

f u e ls t o p r o d u ce a cle a n a ir g a so lin e in m a n y a r e a s.

The use of this type of blended fuel is recommended.

E TH AN OL —U n lea d ed g a sol in e a n d et h a nol

blended fuels are a mixture of 10 percent ethan ol and

90 percent unleaded ga soline. This is an acceptableblend of fuel.

MTBE— MTBE blended fuels are a mixture of un-

leaded gasoline and up to 15 percent MTBE (Methyl

Te rt i a r y B u t y l E t h e r ). U n l ea d e d g a s ol in e b le nd ed

with MTBE is acceptable.

ETB E— This fuel is a mixture of unleaded ga soline

a n d u p t o 17 p er ce nt E TB E (E t h y l Te rt i a r y B u t y l

Et h e r ) . U n le a d e d g a so lin e ble n d e d w it h ET B E is a c-

ceptable.

M E TH AN OL —D o n ot u se u n lea d ed g a s ol in e

blended with methanol. The use of this type of alcohol

ca n r e sult in e n gin e p e r for m a n ce d e t e r ior a t io n a n d

da ma ge to crit ical components.

Engine problems that result from use of

methanol possibly will not be covered by new

vehicle warranty.

ADDITIVES MI XED WITH GASOLINE

U s e of f u el s y s t em cl ea n i n g a d d i t iv es s h ou ld b e

avoided. Many of these solutions could conta in h ighly

active solvents.

VACUUM OPERATED, EMISSION CONTROL COM-PONENTS

The vacuum operated emission control componentssh ou ld be se r viced a t in t er va l sp ecif ied in m a in t e -

nance schedule.

Refer to G roup 25—Emission C ontrol S ystems for

addit ional information.

EXHAUST GAS RECIRCULATION (EGR) SYSTEMRe pla ce EG R va lve a n d t u be, a n d cle a n p a ssa g es a t

interval specified in applicable ma intenance schedule.

I f n e ce ssa r y , r e fe r t o G r o u p 25—Em ission C on t r o l

Systems for addit ional information.

Fig. 5 Engine Air Cleaner

Fig. 6 CCV System—4.0L Engine




OXYGEN (O2) SENSOR

Replace O2

sensor a t interval specified in applicable

ma intenan ce schedule.

IGNITION CABLES, DISTRIBUTOR CAP AND RO-TOR

Replace ignit ion cables, distributor cap, a nd r otor a t

interval specified in applicable ma intenance schedule.Re f e r t o G r o u p 8D — I g n it io n S y st e m s f o r a d d it io n a l

information.

IGNITION TIM INGTes t a n d a d ju s t , i f n ece ss a r y, i gn i t ion t i m in g a t

interval specified in applicable ma intenance schedule.

Refer to specifications listed on engine Emission Con-

t r o l I n f or m a t ion la be l. Re fe r t o G r ou p 8D —I g n it ion

Systems and to Group 25—Emission Control Systems

for addit ional service information.

SPARK PLUGSRe pla ce sp a r k p lu g s a t in t er va l sp ecif ie d in a p p li-

ca ble m a in ten a nce s ch ed ule. R efer t o G r ou p

8D—Ignition Syst ems for addit ional informat ion.

BATTERYRe pla ce ba t t e r y a t in t er va l sp ecif ie d in a p p lica ble

ma intenan ce schedule.


T h e ba t t e r y a cid le ve l sh o u ld be ch e ck e d a n d t h e

cable clamps should be inspected for corrosion. This

sh o u ld be d o n e w h e n t h e e n g in e o i l is ch a n g e d a n d

the oil filter is replaced.

The battery cables should be inspected for abnormal

cla m p a n d ba t t e r y t e r m in a l p ost cor r osion . S e r vice

the terminals and cable clamps as necessary.

INSPECTION/SERVICE

WARNING: WEAR SAFETY GLASSES, RUBBER

GLOVES AND PROTECTIVE CLOTHING WHEN

HANDLING/SERVICING A BATTERY. THE BATTERY

CONTAINS SULFURIC ACID AND WILL CAUSE

HARM IF IT CONTACTS SKIN, EYES OR CLOTHING.

IT WILL ALSO DAMAGE PAINTED (AS WELL AS

UN-PAINTED) SURFACES OF A VEHICLE. IF SULFU-RIC ACID CONTACTS ANY OF THESE, FLUSH IMME-

DIATELY WITH LARGE AMOUNTS OF WATER. IF

SULFURIC ACID CONTACTS SKIN OR EYES, GET

IMMEDIATE MEDICAL ATTENTION. DO NOT SMOKE

IN THE VICINITY OF A BATTERY. KEEP OPEN

FLAMES AND SPARKS AWAY FROM BATTERY

FILLER CAPS BECAUSE EXPLOSIVE GAS IS AL-

WAYS PRESENT.

(1) D iscon n e ct t h e ba t t e r y n e ga t ive ca ble a n d t h e n

the positive cable.

(2) C l ea n t h e b a t t e r y ca b l e c la m p s a n d t e rm i n a l

pos t s w it h a w ir e b r us h a n d a b a tt er y t er min a l

cleaner.

(3) P r y t h e b a t t e ry cel l f i ll er ca p s u pw a r d t o r e-

move them and inspect each filler well. It could possi-

b ly b e n ece ss a r y t o l oos en t h e b a t t e ry h ol d dow n

cl a m p t o r em ov e t h e ca p s . M a i n t a i n t h e a c id l ev el

a b ov e t h e b a t t er y pl a t es a n d a t t h e b ot t om of t h ef i l le r w e ll r in g . Ad d d ist i l le d w a t e r o r lo w - m in e r a l

con t en t d r in k in g w a t er, i f n ece ss a r y. I n f r ee zi n g

weat her (below 0°C/32° F), a dd the w at er just before

d r ivin g t o e n su r e t h a t i t m ix e s. T h is w il l p r e ve n t i t

from freezing.

(4) Re m o ve t h e ba t t e r y h o ld d o w n st r a p a n d cle a n

t h e ba t t e r y ca se/ba t t e r y t r a y . C le a n w it h a bica r bo n -

a t e of s od a a n d w a t e r. R in s e a n d d r y t h e b a t t er y

case/tr ay th oroughly a fter cleaning.

(5) P o s it i on t h e b a t t e r y i n t h e t r a y a n d i n st a l l t h e

holddown strap. Do not over-tighten the nuts.

(6) Connect the battery posit ive cable and then thenegative cable to the battery.

(7) Ap p ly a sm a ll a m o u n t o f ch a ssis lu br ica n t ( o r

a n e q u iva le n t p r ot e ct ive coa t in g ) t o t h e ca ble t e r m i-

nals to minimize corrosion.

RUBBER/PLASTIC COMPONENTS

INSPECTION

It is recommended t ha t following listed components

be in sp ect ed a t sa m e t im e a s sch e d uled u n d er h ood

ma intena nce is conducted. R ubber/plast ic components

sh ou ld be r e pla ced im m ed ia t e ly i f t h e r e is a n y e vi-

dence of deterioration.Inspect exterior surface of rubber hoses and nylon

tubing for evidence of heat damage. The rubber hose

an d nylon tubing locat ed close to an exha ust m an ifold

should be given a ttention. Verify nylon tubing located

at these areas has not collapsed.

Inspect rubber hose routing to ensure that hoses do

not conta ct a ny heat source or moving component.

Inspect all hose connections. Verify they are secure

and there is no fluid leakage.

ENGINE MOUNTS

Inspect rubber in the engine mounts for excessivew e a r . S l ig h t w e a r a t e n d s w il l n o t a f f e ct f u n ct io n in g

of an engine mount. If excessive engine movement is

detected, engine mount(s) should be replaced.

SERPENTINE DRIVE BELTReplace drive belt and adjust drive tension at inter-

va l sp ecif ied in a p p lica ble m a in t e n a n ce sch e d ule. I f

necessary, refer to Group 7—Cooling Systems for re-

placement and adjustment and procedures.




INSPECTION

I t i s r ecom m en d ed t h a t s er pen t i n e d r i ve b el t b e

routinely inspected for cracks, fraying and excessive

wear.

EXHAUST SYSTEMAn e xh a u s t s y s t em m u s t b e p r op er l y a l i gn ed t o

prevent st ress, leakage, a nd vehicle body conta ct .

I n sp e ct e x h a u st sy st e m a t in t e r va l sp e cif ie d in a p -

plicable m aint enance schedule.

INSPECTION

Inspect for cracked or loose joints, corrosion dam -

age, and worn or broken hangers. Replace all compo-

n e n t s t h a t a r e d a m a g e d . D o n ot a t t e m p t r e pa ir .:

• Exhaust system leaks, misalignment

• Contact with body panels or frame

• Catalytic converter bulging or excessive heat dam-

a ge

CAUTION: A catalytic converter will become con-

taminated if leaded gasoline is burned in engine. If

this occurs, complete converter must be replaced.

AIR-CONDITIONER COM PRESSOR

LUBRICANT AND REFRIGERANT

The lubrican t level in air-conditioner compressor

should be checked if there are indicat ions t hat oil w as

lost . Loss of lubricat ing oil usually accompanies a loss

of refrigera nt . The presence of bubbles in filter/drier

sig h t g la ss in d ica t e s t h a t loss o f r e f r ig er a n t h a s oc-

curred.

For addit iona l informa tion involving A/C system,

refer to Group 24—Heater And Air Conditioning.




DRIVETRAIN

INDEX

page page

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Clutch and Brake Pedal Bushings . . . . . . . . . . . . . 17Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . 17

Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Transfer Case (4WD Vehicles) . . . . . . . . . . . . . . . 18Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CLUTCH AND BRAKE PEDAL BUSHINGSIf clutch and brake pedal mechanism squeaks, pivot

bu sh in g s sh ou ld be lu br ica t e d . U se MO PARMulti-

Purpose Lubricant, or an equivalent.

CLUTCH MASTER CYLINDER

HYDRAULIC FLUID LEVEL

Th e clu t ch m a st e r cyl in de r f luid level sh ou ld be

inspected at sam e t ime a s scheduled underhood main-

t e n a n ce is con d u ct e d . Th e f luid level sh ou ld be a t

internal indicating line (Fig. 1). I f f luid level is low,

loca t e a n d cor r e ct a n y p ossible lea k s. F i l l r e se r voir

with clean, moisture-free brake fluid.

CAUTION: Do not allow any petroleum base fluids tocontaminate clutch hydraulic system because sealdamage will result.

FLUID SPECIFICATION

Th e on ly fluid recom men ded for use is

MOPARB r a k e F lu id , o r a n e q u iva le n t p r o d u ct . T h e

p r od u ct is id en t i f ie d a s S AE J -1703 o r D O T 3 f lu-id .Do not use any other type of fluid.

CAUTION: Never use reclaimed brake fluid or fluidfrom an unsealed container. Do not use fluid that

has been opened and allowed to stand for an ex-tended length of time.

TRANSMISSIONS

SPECIAL ADDITIVES

C h r y sler Mot o r s d oe s n ot r e com m e n d a d d it ion of

a n y s pe ci a l a d d i t iv es t o a t r a n s m is s ion . B l a c k l ig h tdetection dye can be used as an aid in detecting fluid

leaks.

GEAR SHIFTER BOOTS

Inspect shifter boots periodically for stone a nd heat

dam age. Replace, if necessary.

SEVERE DRIVING CONDITIONS

Th e in t e r va l bet w e e n t r a n sm ission d r a in a n d r e fi ll

ma intenan ce should be decreased to:

• AX15 m a n u a l t r a n s m i ss ion —e ver y 29 000 k m

(18,000 miles)

• Automatic transmission—every 19 000 km (12,000

miles)

A severe driving condition includes:

• Extended operation with heavy cargo loads

•

Driving in deep mud or snow • Off-road operation (4WD)

• Tra iler t owing

• Opera tion a s a commercial vehicle

• Snow plowing

MANUAL TRANSMISSIONS

INSPECTION/LUBE OIL LEVEL

Th e m a n u a l t r a n sm ission sh ou ld be in sp ect e d f or

lea k a g e w h e n eve r ot h e r se r vice is n e ce ssa r y u n d er

vehicle. To check lube oil level, remove fill h ole plug

(F ig . 2 ). I f leve l is below bot t o m of f il l h o le, r a ise

level to bottom of fill hole with:• S AE 75W90, API Q u a li t y G r a d e G L -5 g e a r lu br i-

cant

DRAIN AND FILL

Th e AX 15 t r a n sm ission f luid sh ou ld be ch a n g e d

according to interval listed in Maintenance Schedule.

Also, refer to Fluid C apa cit ies chart .

Fig. 1 Fluid Level Indicating Ring




AUTOMATIC TRANSMISSIONS

FLUID LEVEL

I t is r e com m e n d ed t h a t f luid (ATF ) le vel in a u t o -

m a t ic t r a n sm issio n s be ch e ck e d w h ile in vo lve d w it h

other underhood ma intenance.

Vehicle operation with an incorrect ATF level

will greatly reduce life of transmission.

The condition of ATF also should be determined. If

ATF i s d a r k i n col or a n d h a s a s t r on g od or, f lu id

should be changed. Also filter sh ould be replaced an d

ba n d s a d ju st e d .

The following procedure must be used to check au-

toma tic t ra nsmiss ion fluid (ATF) level.

(1) Position vehicle on level ground.

(2) Opera te engine a t idle speed.(3) Apply parking brake.

(4) P lace gear selector in N (neutra l).

(5) Remove dipstick from tube. Wipe it clean an d

determine if ATF is hot or warm.

Hot ATF has a temperature of approximately

82°C (180°F). Warm ATF is when its temperature

is between 29-52°C (85-125°F).

(6) Wipe dipstick clean and completely insert it into

t u be. Re m ove d ipst ick f r om t u be a n d obser ve ATF

level.

(7) If ATF is hot , level should be in crosshat ched

a r e a t h a t is m a r k e d O K .(8) I f ATF is w a r m , level sh ou ld be be t w e en t w o

dimples.

CAUTION: Do not overfill transmission.

(9) Adjust level of ATF a ccordin gly.

It is important to use correct fluid in AW4

automatic transmission. Mercon™ ATF should

be used.

(10) Insert dipstick into t ube.

DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL

T h e Ma in t e n a n ce S ch e d u le ch a r t l ist s in t e r va ls a t

which transmission should be serviced. Also, refer to

Fluid Ca pacit ies cha rt for fill capacity.

The torque converter does not have a drain plug. No

a t t e m p t sh o u ld be m a d e t o d r a in co n ve r t e r . Re f e r t o

G roup 21—Tran smissions for tra nsmission dra in a nd

refill procedures.

TRANSFER CASE (4WD VEHICLES)

INSPECTION

Th e t r a n sf e r ca se f luid level sh ou ld be ch ecke d

wh enever ma intenance is necessary un der vehicle.

FLUID LEVEL

The vehicle must be level when fluid level is

checked.

The tr a nsfer ca se dra in/fill hole plugs a re loca ted a t

rear of housing (Fig. 3).

Determine tr an sfer case fluid level a ccording to fol-lowing procedure.

(1) Ra ise an d support vehicle.

(2) Remove fill hole plug (Fig. 3). The fluid level

should be a t bottom edge of f ill hole. The level can be

slightly below bottom edge of fill hole if fluid is cold.

(3) I f le vel is n ot a cce pt a ble, r a ise f lu id level t o

bottom edge of fill hole with:

• MOPARATF P L U S or a n e qu i va l en t D e xr on I I

ATF.

Add fluid in small amounts to raise level.

(4) Inst all f ill hole plug (Fig. 3). Tighten fill hole

plug to 27 N¼m (20 ft-lbs) t orque.(5) Remove support and lower vehicle.

FLUID DRAIN AND REFILL

(1) Ra ise an d support vehicle.

(2) Remove fill hole plug (Fig. 3) from transfer case.

(3) Pla ce a n a p p r op r ia t e con t a in e r u n d er t r a n sf e r

case drain hole plug (Fig. 3).

Fig. 2 Manual Transmission Fill/Drain Hole Plugs

Fig. 3 Transfer Case—Typical




(4) Remove drain hole plug. Drain fluid from trans-

fer case into container.

CAUTION: Do not over-tighten drain and fill hole

plugs.

(5) I n st a l l d r a in h ole p lu g (F ig . 3). Tig h t en d r a in

hole plug to 27 N¼m (20 ft-lbs) torque.

(6) F i ll t r a n s f er ca s e t o b ot t om e dg e of f il l h ol e

w i t h :

• MOPARATF P L U S or a n e q ui va l en t D e xr on I I

ATF

(7) I n st a l l f i ll h ole p lu g . Tig h t en p lu g t o 27 N¼m

(20 ft-lbs) torque.

(8) Remove support and lower vehicle.

FLUID SPECIFICATION

• MOPARATF P L U S or a n e q ui va l en t D e xr on I I

ATF

SHIFT MECHANISM Th e t r a n sf er ca s e s h if t m ech a n is m s h ou ld b e

cle a n e d a n d lu br ica t e d a s n e ce ssa r y t o m a in t a in e a se

of operation.

Lubricate pivot , sliding contact areas and shift link-

age pivot ends with light-weight engine oil (Fig. 4).

AXLES

INSPECTION For normal vehicle opera tion, periodic a xle lubri-

cant level checks are not necessary. However, exterior

of a x l e h ou s in g s h ou ld b e i n sp ect e d f or l ea k a g e .

Check lubrican t level to confirm leakage.

LUBRICANT LEVEL

(1) Ra ise ve h icle w it h a n a x le o r w h e e l t y p e h o ist .

Support vehicle.

(2) The rear axle differential housings have a rub-

ber, P RES S -I N t y p e f i l l p lug (F ig . 5). P r y f il l p lu g

from differential housing. The front axle (4WD ve-

hicles) differential housings have a threaded-type fill

plug (Fig. 5). Remove fill plug from differential hous-

ing.

(3) The lubr icant level should be w ithin 12 mm (1/2

in) of fill hole.

(4) If necessar y, a dd lubricant .

(5) Inst all f ill hole plug in d ifferential housing (Fig.

5).

DRAIN AND REFILLP e r iod ic a x le lu br ica n t ch a n g e f or n or m a l veh icle

operation is n ot n ecessary. However, lubricant should

be cha nged if it is conta mina ted. Refer t o cha rt below-

.All axles contain SAE 80W-90 multi-purpose

type hypoid gear lubricant when delivered from

factory.

Use same maintenance procedures for rear ax-

les equipped with a limited-slip differential.

Fig. 4 Shift Mechanism Lubrication—Typical

Fig. 5 Axle Fill Plug Location—Typical

LUBRICANT VISCOSITIES FOR ANTICIPATED

TEMPERATURE RANGES




CAUTION: Water contaminated gear lubricant willresult in possible failure of axle differential compo-nents. Operation of vehicle in water, will requirethat:

• The lubricant be dra ined

• The differential housing flushed (except limited-

slip differentials)

• The differential refilled with fresh lubricant

LUBRICANT SPECIFICATION

A multi-purpose, hypoid gear lubrican t should be

used in all axles equipped with either a standard or a

limited-slip differential. The use of MOPAR S y n -

t h et i c Ax le L u be i s n ece ss a r y w i t h t r a i le r t ow i n g

packa ge. Tra c—Loc axles require a friction add itive.

FRONT AXLE PIVOT BEARINGS (4 W/D)

Th e f r on t a x le u n iver sa l join t a n d p ivot bea r in g s

a r e p e r m a n e n t ly lu br ica t e d a n d n o r m a lly d o n o t r e -

quire service.

DRIVE SHAFTS

SLIP-YOKE LUBRICATION

Wh en eq u ip pe d w i t h l ub e f it t i n gs , i t i s r ecom -

mended t ha t slip-yoke splines be lubricated every 9

600 k m (6,000 m iles). F o r seve re u sa g e , lu br ica t e

splines every 1 600 km (1,000 miles).

The method described below will ensure complete

lubricat ion of s lip-yoke splines.

(1) Clean Zerk ty pe lubrication fit t ings.

(2) Use a lubricant dispenser to force lubricant into

slip yoke Zerk type lubrication fit t ings.

(3) C on t in u e lu br ica t in g u n t i l i t a p p ea r s a t p r es-

sure relief hole in expansion plug located at slip-yoke

end.

(4) C o ve r p r essu r e r e l ie f h ole w it h a f in g e r. C o n -

tinue to force lubricant into fit t ing until it appears at

slip-yoke seal.

U-JOINT/CV-JOINT LUBRICATION

L ub rica t ion of u -join t cou pler s t h a t a r e n ot

e q u ip pe d w it h lu be (Z er k ) f i t t in g s is n ot n e ce ssa r y .

Replacement U -joints ar e equipped w ith lube fit t ings.I f in st a l led , lu br ica t e t h e m a ccor d in g t o in f or m a t io n

provided below.

Lubricat e U-joint an d CV-joints every 12 000 km

(7,500 m iles) for L IG HT DU TY CYCLE vehicles. For

HE AVY DU TY CYCLE vehicles, couplers should be

lubricated every 9 600 km (6,000 miles). If vehicle is

operat ed in w a ter, U -joint /CV-joint couplers should be

lubricat ed daily.

I f a veh icle, is u sed in a se ve r e d r ivin g con d it ion ,

lubricat e U-joint/CV-joints every 4 800 km (3,000

miles).

A severe driving condition includes:

• Off-road driving

• Driving in deep mud or snow

• When 1/3 or more of vehicle operation involves

driving wit h a full-load.

LUBRICANT SPECIFICATION

Dr ive sh a ft slip yokes a nd U -joint /CV-joint couplers

s h ou ld b e l u b ri ca t e d w i t h , N L G I G C -L B l ub r ica n t .

The U-joints/CV-joint couplers should be lubricat ed

w i t h M OP ARM u lt i pu r pos e L u br i ca n t , N L G I G C -

LB).




CHASSIS AND BODY

INDEX

page page

Body Component Mechanisms . . . . . . . . . . . . . . . 23Front Suspension Ball Joints . . . . . . . . . . . . . . . . 21Front Wheel Bearings . . . . . . . . . . . . . . . . . . . . . 22Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Lower and Upper Suspension Arm Bushings . . . . . 22

Power Brake System . . . . . . . . . . . . . . . . . . . . . . 22Power Steering System . . . . . . . . . . . . . . . . . . . . 21Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 24Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . 21Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

STEERING LINKAGE

INSPECTION

Whenever a vehicle is ra ised for lubr ication/general

ma intenan ce under vehicle, a ll st eering components

should be inspected.

LUBRICATION SCHEDULE

The steering linkage is lubricated during manufac-ture with a long-life chassis lubricant . However, it is

r e com m e n d ed t h a t l in ka g e be in sp ect ed a n d lu br i-

cated after each:

• 24 000 k m (15, 000 m i les ) i n t er v a l or ev er y 6

m on t h s, f or 2WD veh icles su bje ct t o L I G H T D U TY

CYCLE Maintenance Schedule

• 9 600 km (6,000 miles) interval or every 6 months,

for 2WD vehicles subject to HE AVY D UTY CYCLE

Maintenance Schedule

• 12 000 k m (7, 500 m il es ) i nt er va l or ev er y 6

m on t h s, f or 4WD veh icles su bje ct t o L I G H T D U TY

CYCLE Maintenance Schedule• 9 600 km (6,000 miles) interval or every 6 months,

for 4WD vehicles subject to HE AVY D UTY CYCLE

Maint enance S chedule.

LUBRICATION

(1) Inspect steering linkage for looseness and exces-

sive wear.

(2) Re p la ce , a l l r u p t u r ed se a ls a n d d a m a g ed st e er -

ing linkage components.

CAUTION: Use care to prevent lubricant from con-tacting brake rotors.

(3) Lubricat e steering linkage:

• Clean Zerk type lubrication fit t ings on t ie-rod and

center link ball-stud ends

• L u br i ca t e b a l l s t u d s w i t h M OP ARMulti-Mileage

Lubricant

• Wipe excess lubricant from exterior surfaces of ball joints

FRONT SUSPENSION BALL JOINTS

INSPECTION

Wh e n a veh icle is r a ise d f or lu br ica t io n /g en e r a l

ma intenan ce, ba ll joints should be inspected.

LUBRICATION SCHEDULE

Th e f ron t s us pen sion b a ll join t s a r e s em i-

p er m a n e nt l y l ub r ica t e d d u r in g m a n u f a ct u r e w i t h a

special, long-life chassis lubrican t . However, it is rec-

om m en d ed t h a t b a l l joi n t s b e i n sp ect e d a n d s t u d s

lubricated:

• At each 36 000 km (22,500 miles) interval or every

2 years, for vehicles subject to LI G HT DUTY C YCLEMaintenance Schedule

• At each 9 600 km (6,000 miles) interval or every 2

years, for vehicles subject to H EAVY DU TY C YCLE

Maint enance Schedule.

4WD vehicles that are frequently driven off-

road should be lubricated at every engine oil

change.

LUBRICATION

(1) Inspect front suspension.

(2) R e pl a ce a l l t or n b a l l-s t u d s ea l s a n d d a m a g e d

ball joints. Damaged seals should be replaced to pre-

vent leakage and contamination.

CAUTION: Use care to prevent lubricant from con-tacting brake rotors.

(3) Lubricate ball studs:

• C lea n Z er k t y p e lu br ica t ion f it t in g s on ba l l-st u d

ends

• L u br i ca t e b a l l s t u ds w i t h M OP ARMulti-Mileage

Lubricant

• Wipe excess lubricant from exterior surfaces of ball

joints

POWER STEERING SYSTEMFLUID LEVEL

WARNING: THE POWER STEERING FLUID LEVELSHOULD ALWAYS BE DETERMINED WITH THE EN-GINE OFF TO PREVENT PERSONAL INJURY FROM

ROTATING ENGINE COMPONENTS.

The power steering fluid should be checked when-

ever engine is being serviced for other reasons. C lean

outside of cap before removing. The fluid should be at

proper level indicated on cap dipstick (Fig. 2).




Th e r e ser voir f luid level ca n be d e t er m in ed w it h

fluid either hot or cold. If f luid level is below FULL

H O T o r F U L L C O L D m a r k s o n d ip st ick , a d d p o w e r

st e er in g f luid . Th e d ipst ick is a t t a ch e d t o r e se r voir

cap (Fig. 2).

FLUID SPECIFICATION

Use only MOPARPower Steering Fluid.

FRONT WHEEL BEARINGSThe front w heel bearings on a ZJ vehicle are perma-

n en t l y l ub r ica t e d . I f s er v ice i s n eces s a r y r ef er t o

G roup 2—Front Su spension And Axle.

LOWER AND UPPER SUSPENSION ARM BUSH-INGS

INSPECTION SCHEDULE

Th e l ow e r a n d u pp er s u sp en s ion a r m b us h in g s

should be inspected each t ime underside of vehicle is

serviced.

INSPECTION

The lower suspension arm bushings can be visually

inspected by raising vehicle on a hoist and inspecting

f r om u n d er n e a t h . Th e u p pe r su spe n sion a r m bu sh -

ings can be inspected after removing front wheels. I f

f a il ur e ex is t s, r epl a ce b us h in g (r ef er t o G r ou p

2—Front Su spension for proper procedures).

The suspension arm bushings never should be

lubricated.

GUIDELINES

(1) F a u lt y bu sh in g s a r e d e t e ct e d by bu sh in g be in g

off-center in relation to outer sleeve.(2) Tota l failure is evident by excessive m ovement

within bushing.

(3) Small cracks in outer, non-confined rubber does

not indicat e fa ilure of rubber.

POWER BRAKE SYSTEMVe h icle s a r e e q u ip pe d w it h p ow e r d isc br a k e s a t

f r on t w h e e ls a n d d r u m br a k e s a t r e a r w h e els.

FLUID SPECIFICATION

P ow e r br a k e sy st e m s r e q u ir e MO PARHeavy-Duty

B r a k e F lu id.Th e u se o f a n e q u iva le n t p r od u ct id en t i f ie d w it h

FMVSS No. 116, DOT-3 an d SAE J -1703 S ta nda rd

designations is permissible.

U s e f r es h b r a k e f lu id on l y w h en a d d i ng f lu id t o

r e ser voir. N e ve r u se f lu id t h a t d oe s n o t con f or m t o

D O T/S AE S t a n d a r d s, or f luid f r om a con t a in e r t h a t

has been left open.

CAUTION: The use of a substandard brake fluid

could result in sudden brake failure during hard,

prolonged braking.

CAUTION: Do not allow petroleum base fluids to

contaminate brake fluid. Seal damage will result.

BRAKE FLUID LEVEL

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system fluid reservoir is located

in engine compartment at left side of dash panel.

(1) Clean cover before removing it.

Fig. 1 Steering Components—Typical

Fig. 2 Power Steering Reservoir & Cap—Typical




CAUTION: Over-filling could cause fluid overflow

and possible reservoir damage when pump motor

energizes.

(2) T h e br a k e f lu id le ve l sh o u ld be n o lo w e r t h a n

MI N a r r o w in d ica t or on sid e of r e se r voir. I f n ot , a d d

br a k e f lu id a s n e ce ssa r y . Ra ise f lu id leve l t o MAX

arrow indicator only. Do not over-fill reservoir.

BRAKE SYSTEM INSPECTION

(1) I n sp ect br a k e p a d s a n d l in in g s f or e xcessive

wea r, cracks a nd broken rivets.

(2) I n sp e ct br a k e p a d s a n d l in in g s f o r co n t a m in a -

tion w ith brake fluid, a xle lubricant an d/or other flu-

ids.

(3) Replace front brake pads and rear brake liningsif t hey a re w orn t o wit hin 0.78 mm (1/32 in) of a rivet

h e a d .

(4) O per a t e r ea r b r a k e s el f-a d ju s t er l ev er a n d

pivot. Test opera tion of self-a djuster screw for eas e of

movement.

(5) I n sp ect se lf -a d ju st er com p on e n t s f or f r a y e d

cables. Inspect for loose or overheated springs, or a

binding condition.

(6) Inspect caliper dust boots for damage or tears.

I n sp e ct f o r a n in d ica t io n o f br a k e f lu id le a k a g e . I n -

sp ect bu sh in g s a n d p in s f or cor r osion . I n sp ect f or

tears or a binding condition.

(7) Inspect rear wheel cylinder dust boots for fluid

leaks. I nspect pistons an d cylinder bores for proper

appearance.

(8) I n s pe ct b r a k e d if fe re nt i a l w a r n i n g v a l ve a n d

housing for indications of leakage, kinked hoses and

loose fittings.

BRAKE HOSES/TUBING

The rubber brake hoses should be inspected for:

• Correct length

• Severe surfa ce cracking

• Swelling

• Pulling

• Scuffing

• Excessively worn areas

(1) Inspect all hoses for kinks, a distorted condition

and fluid leakage.

(2) Inspect hose and tubing routing under vehicle.

Ve ri fy t h a t n o h os e/t u b in g i s r u bb in g a g a i n s t a n y

underbody components.

PARK BRAKE

(1) Engage park brake lever and then release it .

(2) Te st p a r k in g br a k e f or sm oot h op er a t io n a n d

vehicle-holding capability.

(3) Inspect park brake cables for kinks, fraying and

a binding condition.

(4) Wit h p a r k br a k e r e le a sed , r e a r w h e els sh ou ld

r ot a t e w it h o u t r e st r ict ion . Ad ju st p a r k br a k e ca ble

t e n sion a t e q u a liz er. Re fe r t o G r ou p 5—B r a k e s, f o r

component information.

(5) Repair any park brake malfunctions.

BRAKE OPERATIONAL TEST

(1) Drive vehicle and test for proper bra ke action.

(2) Note any indicat ion of bra ke overheating, w heel

dragging or vehicle pulling to one side.

(3) Eva luate an y performa nce complaints received

from own er/operat or.

(4) R ep a i r b r a k e s y s t em a s n ece ss a r y (r ef er t o

G r ou p 5—B r a k es f or a d d it ion a l in for m a t ion a n d se r-

vice procedures).

BODY COMPONENT MECHANISMS

LUBRICATION REQUIREMENTS

All o p e r a t in g m e ch a n ism s a n d l in k a g e s sh o u ld be

lubricated when necessary. This will maintain ease of

op er a t i on a n d p rov id e p rot e ct i on a g a i n s t r u st a n d

e xce ssive w e a r. D o or w e a t h e r st r ip se a ls sh ou ld be

lu br ica t e d t o p r olon g t h e ir l i f e a s w e ll a s t o im p r ove

door sealing.

LUBRICANT SPECIFICATIONS

All applicable exterior and interior vehicle operat-

ing mechanisms should be:

• Inspected

• Cleaned

• All pivoting/sliding conta ct ar eas on mechan isms

should t hen be lubricat ed.

MOPARMulti-Mileage Lubricant or an equivalent,

sh ou ld be u sed t o lu br ica t e m e ch a n ism s. Th e d oor

weatherstrip seals should be lubricated with silicone

lu br ica n t sp r a y. Re fe r t o B o d y L u br ica n t S p ecif ica -

t i on s ch a r t b el ow f or a d d i t ion a l l ub r ica n t a p pl ica -

tions.

LUBRICATION

(1) When necessa ry, lubricat e body component op-

erating mechanisms with specified lubricants.

Fig. 3 Reservoir Fluid Level—Anti-Lock Brake Sys-

tem




(2) Apply silicone lubrican t to a cloth. Wipe it on

door seals to avoid over-spray that can soil passenger

clothing.

(3) B efore a pplying lubricant , component should be

w ip ed cle a n . Af t e r lu br ica t io n , a n y e xcess lu br ica n t

should be removed.

(4) The hood latch, latch release mechanism, latch

striker and safety latch should be lubricated periodi-

cally.

(5) The door lock cylinders should be lubricated 2

times each year (preferably autumn and spring):

• S p r a y a s m a l l a m o un t of l ock cy l in d er l ub r ica n t

directly into lock cylinder

• Apply a small amount to key and insert it into lock

cylinder

• Ro t a t e i t t o lo ck e d p o sit io n a n d t h e n ba ck t o u n -

locked position several times• Re m ove k e y. Wipe lu br ica n t f r om i t w it h a cle a n

cloth to avoid soiling of clothing.

TIRES


The condition of t ires should be inspected. The in-

f la t ion p r essu r es t e st ed /cor r e ct e d a t sa m e t im e a s

engine oil is changed a nd oil f ilter is replaced.

The t ires/wheels should be rotated periodically to

t d Th t i / h l h ld b

r ot a t e d a t f ir st 12 000 k m (7,500-m ile s) in t e r va l .

Thereaft er, a t each 24 000 km (15,000-miles) interva l.

INSPECTION

Inspect t ires for excessive w ear, da ma ge. Test t iresfor recommended inflat ion pressure. Refer t o G roup

22—Tires And Wheels for t ire pressure chart s, t ire

replacement, and treadwear indicators.

ROTATION

Tires/wh eels sh ould be rota ted a ccording to recom-

mended interval.

Refer to G roup 22—Tires And Wheels for recom-

mended meth od of tire/wh eel rotat ion.

HEADLAMPSEve r y six m o n t h s ch e ck h e a d la m p bea m s t o e n su r e

that headlamp beams are correctly posit ioned.

AIM ADJUSTMENT

R e f e r t o G r o u p 8 L — L a m p s f o r h e a d l a m p a i m a d -

justment procedures.

SPEEDOMETER CABLE

SERVICE INFORMATION

Speedometer cable lubricat ion is not necessary. For

service information involving noisy or erratic cables,

f t G 8E I t t P l d G g

BODY LUBRICANT SPECIFICATIONS


ZJ Lube&Maintenance

Documents

Transcript of ZJ Lube&Maintenance