ENGINE COOLANT                                                                                  TRANSMISSION              ...
WHEEL                                                                BEARINGS               CHASSIS LUBRICA-              ...
XJ                                                                            LUBRICATION AND MAINTENANCE                 ...
0-4     LUBRICATION AND MAINTENANCE                                                                      XJGENERAL INFORMA...
XJ                                                              LUBRICATION AND MAINTENANCE            0-5GENERAL INFORMAT...
0-6     LUBRICATION AND MAINTENANCE                                                                      XJGENERAL INFORMA...
XJ                                                            LUBRICATION AND MAINTENANCE             0-7GENERAL INFORMATI...
POSITIVE                                                                CONNECTION                                        ...
WHEEL LIFT                    FLAT BEDXJ                                                               LUBRICATION AND MAI...
0 - 10    LUBRICATION AND MAINTENANCE                                                                          XJSERVICE P...
FRAME CONTACT          DRIVE-ON HOIST HOIST   TWIN POST CHASSIS HOIST                                 FLOOR JACK          ...
XJ                                                                                       LUBRICATION AND MAINTENANCE      ...
0-2     LUBRICATION AND MAINTENANCE                                                                       XJ              ...
XJ                                                                 LUBRICATION AND MAINTENANCE                0-3GENERAL I...
0-4     LUBRICATION AND MAINTENANCE                                                                     XJGENERAL INFORMAT...
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  1. 1. ENGINE COOLANT TRANSMISSION AUTOMATIC OIL ENGINE FLUID WINDSHIELDFLUID POWER STEERING BRAKE FLUID WASHER FLUIDXJ LUBRICATION AND MAINTENANCE 0-1 LUBRICATION AND MAINTENANCE CONTENTS page pageGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 3JUMP STARTING, TOWING AND HOISTING . . . . . . . . . . . . . . . . . . . . . . . . 8 GENERAL INFORMATION INDEX page pageGENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 CLASSIFICATION OF LUBRICANTS . . . . . . . . . . 2 PARTS AND LUBRICANT FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 2 RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 1 INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 1GENERAL INFORMATIONINTRODUCTION best engineered products for servicing Chrysler Cor- Service and maintenance procedures for compo- poration vehicles.nents and systems listed in Schedule—A or B can befound by using the Group Tab Locator index at the INTERNATIONAL SYMBOLSfront of this manual. If it is not clear which group Chrysler Corporation uses international symbols tocontains the information needed, refer to the index at identify engine compartment lubricant and fluidthe back of this manual. inspection and fill locations (Fig. 1). There are two maintenance schedules that showproper service based on the conditions that the vehi-cle is subjected to. Schedule— A , lists scheduled maintenance to beperformed when the vehicle is used for general trans-portation. Schedule— B , lists maintenance intervals for vehi-cles that are operated under the conditions listed atthe beginning of the Maintenance Schedule section. Use the schedule that best describes your drivingconditions. Where time and mileage are listed, follow theinterval that occurs first.PARTS AND LUBRICANT RECOMMENDATIONS When service is required, Chrysler Corporationrecommends that only Mopar௡ brand parts, lubri- Fig. 1 International Symbolscants and chemicals be used. Mopar provides the
  2. 2. WHEEL BEARINGS CHASSIS LUBRICA- TION CHASSIS BEARINGS WHEEL AND0-2 LUBRICATION AND MAINTENANCE XJGENERAL INFORMATION (Continued)CLASSIFICATION OF LUBRICANTS quality of the lubricant. The following symbols indi- Only lubricants that are endorsed by the following cate the highest quality.organization should be used to service a ChryslerCorporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) (Fig. 2) • National Lubricating Grease Institute (NLGI)(Fig. 3) Fig. 3 NLGI Symbol FLUID CAPACITIES FUEL TANK All . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.4 L (20.2 gal.) ENGINE OIL Fig. 2 API Symbol 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.) 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)ENGINE OIL COOLING SYSTEMSAE GRADE RATING INDICATES ENGINE OIL VISCOSITY An SAE viscosity grade is used to specify the vis- 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qts.)*cosity of engine oil. SAE 30 specifies a single viscos- 4.0L. . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12 qts.)**ity engine oil. Engine oils also have multiple *Includes 2.2 L (2.3 qts) for coolant recovery reservoir.viscosities. These are specified with a dual SAE vis- **Includes 0.9 L (1.0 qt) for coolant recovery reservoir.cosity grade which indicates the cold-to-hot tempera- AUTOMATIC TRANSMISSIONture viscosity range. Dry fill capacity* • SAE 30 = single grade engine oil. • SAE 10W-30 = multiple grade engine oil. AW4 . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L (16.9 pts.) *Depending on type and size of internal cooler,API QUALITY CLASSIFICATION length and inside diameter of cooler lines, or use of an The API Service Grade specifies the type of perfor- auxiliary cooler, these figures may vary. Refer to Groupmance the engine oil is intended to provide. The API 21, Transmission for proper fluid fill procedure.Service Grade specifications also apply to energy con-serving engine oils. MANUAL TRANSMISSION Use engine oils that are API Service Certified. AX5 (4X2) . . . . . . . . . . . . . . . . . . . . . . 3.5 L (3.7 qts.)5W-30 and 10W-30 MOPAR engine oils conform to AX5 (4X4) . . . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qts.)specifications. AX15 (4X2) . . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.) Refer to Group 9, Engine for engine oil specifica- AX15 (4X4) . . . . . . . . . . . . . . . . . . . . . 3.1 L (3.3 qts.)tion. TRANSFER CASEGEAR LUBRICANTS SELEC-TRAC 242 . . . . . . . . . . . . . . . 1.3 L (2.85 pts.) SAE ratings also apply to multiple grade gear COMMAND-TRAC 231 . . . . . . . . . . . . . 1.2 L (2.5 pts.)lubricants. In addition, API classification defines thelubricants usage. FRONT AXLE MODEL 181 . . . . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage REAR AXLEby the NLGI. All approved products have the NLGI MODEL 194 . . . . . . . . . . . . . . . . . . . . 1.6 L (3.5 pts.*)symbol (Fig. 3) on the label. At the bottom NLGI 8-1/4 . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L (4.8 pts.**)symbol is the usage and quality identification letters. * When equipped with TRAC-LOK, include 4Wheel bearing lubricant is identified by the letter ounces of Friction Modifier Additive.“G”. Chassis lubricant is identified by the latter “L”. ** When equipped with TRAC-LOK, include 5The letter following the usage letter indicates the ounces of Friction Modifier Additive.
  3. 3. XJ LUBRICATION AND MAINTENANCE 0-3 MAINTENANCE SCHEDULES INDEX page pageGENERAL INFORMATION SCHEDULE—B . . . . . . . . . . . . . . . . . . . . . . . . . 5 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3 UNSCHEDULED INSPECTION . . . . . . . . . . . . . . 3 SCHEDULE—A . . . . . . . . . . . . . . . . . . . . . . . . . 3GENERAL INFORMATION • Check windshield washer solvent and add if required.INTRODUCTION Service and maintenance procedures for compo- Once A Monthnents and systems listed in Schedule—A or B can be • Check tire pressure and look for unusual wearfound by using the Group Tab Locator index at the or damage.front of this manual. If it is not clear which group • Inspect battery and clean and tighten terminalscontains the information needed, refer to the index at as required. Check electrolyte level and add water asthe back of this manual. needed. There are two maintenance schedules that show • Check fluid levels of coolant reservoir, powerproper service based on the conditions that the vehi- steering, brake master cylinder, and transmissioncle is subjected to. Use the schedule that best and add as needed.describes these conditions. • Check all lights and all other electrical items for Schedule— A , lists maintenance recommended for correct operation.vehicles used for general transportation. Schedule— B , lists maintenance recommended for At Each Oil Changevehicles used under the following conditions: • Inspect exhaust system. • Frequent short trip driving less than 5 miles (8 • Inspect brake hoses.km) • Rotate the tires at each oil change interval • Frequent driving in dusty conditions shown on Schedule—A (7,500 miles) or every other • Frequent trailer towing interval shown on Schedule—B (6,000 miles). • Extensive idling • Check coolant level, hoses, and clamps. • More than 50% of your driving is at sustained • Lubricate slip splines (4 x 4).high speeds during hot weather, above 90°F (32°C) • Lubricate suspension ball joints. • Off road driving • After completion of off-road (4 x 4) operation, the • Desert operation underside of the vehicle should be thoroughly Where time and mileage are listed, follow the inspected. Examine threaded fasteners for looseness.interval that occurs first. SCHEDULE—AEMISSION CONTROL SYSTEM MAINTENANCE The scheduled emission maintenance listed in bold 7,500 Miles (12 000 km) or at 6 monthstype on the Maintenance Schedules, must be done at • Change engine oil.the mileage specified to assure the continued proper • Replace engine oil filter.functioning of the emission control system. These, • Lubricate steering linkage (4x4 only).and all other maintenance services included in thismanual, should be done to provide the best vehicle 15,000 Miles (24 000 km) or at 12 monthsperformance and reliability. More frequent mainte- • Change engine oil.nance may be needed for vehicles in severe operating • Replace engine oil filter.conditions such as dusty areas and very short trip • Lubricate steering linkage.driving. 22,500 Miles (36 000 km) or at 18 monthsUNSCHEDULED INSPECTION • Change engine oil. • Replace engine oil filter.At Each Stop For Fuel • Lubricate steering linkage (4x4 only). • Check engine oil level, add as required. • Inspect brake linings.
  4. 4. 0-4 LUBRICATION AND MAINTENANCE XJGENERAL INFORMATION (Continued)30,000 Miles (48 000 km) or at 24 months • Flush and replace engine coolant if it has been • Change engine oil. 30,000 miles (48 000 km) or 24 months since last • Replace engine oil filter. change. • Replace air cleaner element. • Replace spark plugs. 82,500 Miles (133 000 km) or at 66 months • Inspect adjust drive belt, adjust tension as nec- • Change engine oil.essary. • Replace engine oil filter. • Lubricate steering linkage. • Lubricate steering linkage (4x4 only). • Drain and refill automatic transmission fluid. • Flush and replace engine coolant if it has beenReplace transmission filter. 30,000 miles (48 000 km) or 24 months since last • Drain and refill transfer case fluid. change.37,500 Miles (60 000 km) or at 30 months 90,000 Miles (144 000 km) or at 72 months • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Replace engine air cleaner element. • Drain and refill manual transmission fluid. • Replace spark plugs. • Inspect adjust drive belt, adjust tension as nec-45,000 Miles (72 000 km) or at 36 months essary. • Change engine oil. • Lubricate steering linkage. • Replace engine oil filter. • Drain and refill automatic transmission fluid. • Lubricate steering linkage. Replace transmission filter. • Inspect brake linings. • Drain and refill transfer case fluid. • Flush and replace engine coolant at 36 months, • Inspect brake linings.regardless of mileage. 97,500 Miles (156 000 km) or at 78 months52,500 Miles (84 000 km) or at 42 months • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Lubricate steering linkage (4x4 only). • Flush and replace engine coolant if not done at 105,000 Miles (168 000 km) or at 84 months36 months. • Change engine oil. • Replace engine oil filter.60,000 Miles (96 000 km) or at 48 months • Lubricate steering linkage. • Change engine oil. • Flush and replace engine coolant if it has been • Replace engine oil filter. 30,000 miles (48 000 km) or 24 months since last • Replace engine air cleaner element. change. • Replace ignition cables. • Replace spark plugs. 112,500 Miles (180 000 km) or at 90 months • Inspect adjust drive belt, adjust tension as nec- • Change engine oil.essary. • Replace engine oil filter. • Lubricate steering linkage. • Lubricate steering linkage (4 x 4 only). • Drain and refill automatic transmission fluid. • Drain and refill manual transmission fluid.Replace transmission filter. • Inspect brake linings. • Drain and refill transfer case fluid. • Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last67,500 Miles (108 000 km) or at 54 months change. • Change engine oil. • Replace engine oil filter. 120,000 Miles (192 000 km) or at 96 months • Lubricate steering linkage (4x4 only). • Change engine oil. • Inspect brake linings. • Replace engine oil filter. • Replace engine air cleaner element.75,000 Miles (120 000 km) or at 60 months • Replace ignition cables. • Change engine oil. • Replace spark plugs. • Replace engine oil filter. • Inspect adjust drive belt, adjust tension as nec- • Lubricate steering linkage. essary. • Drain and refill manual transmission fluid. • Lubricate steering linkage.
  5. 5. XJ LUBRICATION AND MAINTENANCE 0-5GENERAL INFORMATION (Continued) • Drain and refill automatic transmission fluid. • Drain and refill front and rear axles.*Replace transmission filter. • Inspect brake linings. • Drain and refill transfer case fluid. Important: Inspection and service should also be 27,000 Miles (43 000 km)performed any time a malfunction is observed or sus- • Change engine oil.pected. • Replace engine oil filter. • Lubricate steering linkage (4x4 only).SCHEDULE—B 30,000 Miles (48 000 km)3,000 Miles (5 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Replace engine air cleaner element. • Lubricate steering linkage (4x4 only). • Replace spark plugs. • Inspect adjust drive belt, adjust tension as nec-6,000 Miles (10 000 km) essary. • Change engine oil. • Lubricate steering linkage. • Replace engine oil filter. • Drain and refill transfer case fluid. • Lubricate steering linkage (4x4 only). 33,000 Miles (53 000 km)9,000 Miles (14 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Lubricate steering linkage (4x4 only). 36,000 Miles (58 000 km)12,000 Miles (19 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Lubricate steering linkage (4x4 only). • Drain and refill manual transmission fluid. • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid.Replace transmission filter. Replace transmission filter. • Drain and refill front and rear axles.* • Drain and refill front and rear axles.* • Inspect brake linings. • Inspect brake linings.15,000 Miles (24 000 km) 39,000 Miles (62 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Inspect engine air cleaner element, replace • Lubricate steering linkage (4x4 only).as necessary. • Lubricate steering linkage. 42,000 Miles (67 000 km) • Change engine oil.18,000 Miles (29 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Lubricate steering linkage (4x4 only). 45,000 Miles (72 000 km) • Drain and refill manual transmission fluid. • Change engine oil. • Replace engine oil filter.21,000 Miles (34 000 km) • Inspect engine air cleaner element, replace • Change engine oil. as necessary. • Replace engine oil filter. • Lubricate steering linkage. • Lubricate steering linkage (4x4 only). 48,000 Miles (77 000 km)24,000 Miles (38 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Lubricate steering linkage (4x4 only). • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid. Replace transmission filter.Replace transmission filter. • Drain and refill front and rear axles.*
  6. 6. 0-6 LUBRICATION AND MAINTENANCE XJGENERAL INFORMATION (Continued) • Inspect brake linings. • Inspect brake linings.51,000 Miles (82 000 km) 75,000 Miles (120 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Inspect engine air cleaner element, replace • Flush and replace engine coolant. as necessary. • Lubricate steering linkage.54,000 Miles (86 000 km) • Change engine oil. 78,000 Miles (125 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Drain and refill manual transmission fluid. • Lubricate steering linkage (4x4 only).57,000 Miles (91 000 km) 81,000 Miles (134 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Lubricate steering linkage (4x4 only). • Flush and replace engine coolant.60,000 Miles (96 000 km) • Change engine oil. 84,000 Miles (134 000 km) • Replace engine oil filter. • Change engine oil. • Replace engine air cleaner element. • Replace engine oil filter. • Replace ignition cables. • Lubricate steering linkage (4x4 only). • Replace spark plugs. • Drain and refill automatic transmission fluid. • Inspect adjust drive belt, adjust tension as nec- Replace transmission filter.essary. • Drain and refill front and rear axles.* • Lubricate steering linkage. • Inspect brake linings. • Drain and refill automatic transmission fluid.Replace transmission filter. 87,000 Miles (139 000 km) • Drain and refill transfer case fluid. • Change engine oil. • Drain and refill front and rear axles.* • Replace engine oil filter. • Inspect brake linings. • Lubricate steering linkage (4x4 only).63,000 Miles (101 000 km) 90,000 Miles (144 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Lubricate steering linkage (4x4 only). • Replace engine air cleaner element. • Replace spark plugs.66,000 Miles (106 000 km) • Inspect adjust drive belt, adjust tension as nec- • Change engine oil. essary. • Replace engine oil filter. • Lubricate steering linkage. • Lubricate steering linkage (4x4 only). • Drain and refill manual transmission fluid. • Drain and refill transfer case fluid.69,000 Miles (110 000 km) • Change engine oil. 93,000 Miles (149 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Lubricate steering linkage (4x4 only).72,000 Miles (115 000 km) • Change engine oil. 96,000 Miles (154 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Drain and refill manual transmission fluid. • Lubricate steering linkage (4x4 only). • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid.Replace transmission filter. Replace transmission filter. • Drain and refill front and rear axles.* • Drain and refill front and rear axles.*
  7. 7. XJ LUBRICATION AND MAINTENANCE 0-7GENERAL INFORMATION (Continued) • Inspect brake linings. 114,000 Miles (182 000 km) • Change engine oil.99,000 Miles (158 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Lubricate steering linkage (4x4 only). 117,000 Miles (187 000 km) • Change engine oil.102,000 Miles (163 000 km) • Replace engine oil filter. • Change engine oil. • Lubricate steering linkage (4x4 only). • Replace engine oil filter. • Lubricate steering linkage (4x4 only). 120,000 Miles (192 000 km) • Change engine oil.105,000 Miles (168 000 km) • Replace engine oil filter. • Change engine oil. • Replace engine air cleaner element. • Replace engine oil filter. • Replace ignition cables. • Inspect engine air cleaner element, replace • Replace spark plugs.as necessary. • Inspect adjust drive belt, adjust tension as nec- • Lubricate steering linkage. essary. • Lubricate steering linkage.108,000 Miles (173 000 km) • Drain and refill automatic transmission fluid. • Change engine oil. Replace transmission filter. • Replace engine oil filter. • Drain and refill transfer case fluid. • Lubricate steering linkage (4x4 only). • Drain and refill front and rear axles.* • Drain and refill manual transmission fluid. • Inspect brake linings. • Drain and refill automatic transmission fluid. *Off-highway operation, trailer towing, taxi, limou-Replace transmission filter. sine, bus, snow plowing, or other types of commercial • Drain and refill front and rear axles.* service or prolonged operation with heavy loading, • Inspect brake linings. especially in hot weather, require front and rear axle service indicated with an * in Schedule—B. Perform111,000 Miles (178 000 km) these services if the vehicle is operated under these • Change engine oil. conditions. • Replace engine oil filter. Important: Inspection and service should also be • Lubricate steering linkage (4x4 only). performed any time a malfunction is observed or sus- • Flush and replace engine coolant. pected.
  8. 8. POSITIVE CONNECTION BOOSTER BATTERY CABLE NEGATIVE CONNECTION CABLE OR GROUND0-8 LUBRICATION AND MAINTENANCE XJ JUMP STARTING, TOWING AND HOISTING INDEX page pageSERVICE PROCEDURES HOISTING RECOMMENDATIONS . . . . . . . . . . 10 EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . 10 JUMP STARTING PROCEDURE . . . . . . . . . . . . . 8 FLAT SURFACE TOWING . . . . . . . . . . . . . . . . 10 TOWING RECOMMENDATIONS . . . . . . . . . . . . . 9 FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . 10 TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . 9SERVICE PROCEDURES (2) When using another vehicle as a booster source, turn off all accessories, place gear selector inJUMP STARTING PROCEDURE park or neutral, set park brake and operate engine at 1200 rpm.WARNING: REVIEW ALL SAFETY PRECAUTIONS (3) On disabled vehicle, place gear selector in parkAND WARNINGS IN GROUP 8A, BATTERY/START- or neutral and set park brake. Turn off all accesso-ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT ries.JUMP START A FROZEN BATTERY, PERSONAL (4) Connect jumper cables to booster battery. REDINJURY CAN RESULT. DO NOT JUMP START WHEN clamp to positive terminal (+). BLACK clamp to neg-MAINTENANCE FREE BATTERY INDICATOR DOT IS ative terminal (-). DO NOT allow clamps at oppositeYELLOW OR BRIGHT COLOR. DO NOT JUMP end of cables to touch, electrical arc will result.START A VEHICLE WHEN THE BATTERY FLUID IS Review all warnings in this procedure.BELOW THE TOP OF LEAD PLATES. DO NOT (5) On disabled vehicle, connect RED jumper cableALLOW JUMPER CABLE CLAMPS TO TOUCH clamp to positive (+) terminal. Connect BLACKEACH OTHER WHEN CONNECTED TO A BOOSTER jumper cable clamp to engine ground as close to theSOURCE. DO NOT USE OPEN FLAME NEAR BAT- ground cable attaching point as possible (Fig. 1).TERY. REMOVE METALLIC JEWELRY WORN ONHANDS OR WRISTS TO AVOID INJURY BY ACCI-DENTAL ARCING OF BATTERY CURRENT. WHENUSING A HIGH OUTPUT BOOSTING DEVICE, DONOT ALLOW BATTERY VOLTAGE TO EXCEED 16VOLTS. REFER TO INSTRUCTIONS PROVIDEDWITH DEVICE BEING USED.CAUTION: When using another vehicle as abooster, do not allow vehicles to touch. Electricalsystems can be damaged on either vehicle.TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visuallyinspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. • Low battery fluid level. • Generator drive belt condition and tension. • Fuel fumes or leakage, correct if necessary. Fig. 1 Jumper Cable Connections—TypicalCAUTION: If the cause of starting problem on dis-abled vehicle is severe, damage to booster vehicle CAUTION: Do not crank starter motor on disabledcharging system can result. vehicle for more than 15 seconds, starter will over- heat and could fail.
  9. 9. WHEEL LIFT FLAT BEDXJ LUBRICATION AND MAINTENANCE 0-9SERVICE PROCEDURES (Continued) (6) Allow battery in disabled vehicle to charge to • Do not allow passengers to ride in a vehicleat least 12.4 volts (75% charge) before attempting to being towed.start engine. If engine does not start within 15 sec- • Always observe state and local laws regardingonds, stop cranking engine and allow starter to cool towing regulations.(15 min.), before cranking again. • Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians orDISCONNECT CABLE CLAMPS AS FOLLOWS: other motorists. • Disconnect BLACK cable clamp from engine • Do not attach tow chains, T-hooks, J-hooks, or aground on disabled vehicle. tow sling to a bumper, steering linkage, drive shafts • When using a Booster vehicle, disconnect or a non-reinforced frame hole.BLACK cable clamp from battery negative terminal.Disconnect RED cable clamp from battery positive GROUND CLEARANCEterminal. • Disconnect RED cable clamp from battery posi- CAUTION: If vehicle is towed with wheelstive terminal on disabled vehicle. removed, install lug nuts to retain brake drums.TOWING RECOMMENDATIONS A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be A vehicle equipped with an SAE approved Wheel- sure there is adequate ground clearance at the oppo-lift towing device can be used to tow all Cherokee site end of the vehicle, especially when towing overvehicles (Fig. 2). When towing a 4WD vehicle, use rough terrain or steep rises in the road. If necessary,tow dollies under the opposite end of the vehicle. A remove the wheels from the lifted end of the vehiclevehicle with a flat-bed device can also be used to and lower the vehicle closer to the ground, totransport a disabled vehicle. increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. FLAT-BED TOWING RAMP ANGLE If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. TWO-WHEEL-DRIVE VEHICLE TOWING TOWING-REAR END LIFTED (SLING-TYPE) CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 2WD XJ vehicles can be towed with the front wheels on the surface for extended distances at Fig. 2 Tow Vehicles With Approved Equipment speeds not exceeding 48 km/h (30 mph). If the vehicleNOTE: A vehicle equipped with a SAE approved is equipped with a factory installed trailer tow pack-sling type towing device can be used to tow a Cher- age, use a SAE approved wheel lift device.okee with the rear end lifted, provided the Cherokee (1) Attach J-hooks around the axle shaft tube out-is not equipped with a factory installed trailer tow board of the shock absorber.package. Damage to the harness connector bracket (2) Place the sling crossbar under and forward ofmay result from sling contact. the bumper. (3) Attach safety chains around the frame rails. (4) Turn the ignition switch to the OFF position toSAFETY PRECAUTIONS unlock the steering wheel. • Secure loose and protruding parts. (5) Secure steering wheel in the straight ahead • Always use a safety chain system that is inde- position with a clamp device designed for towing.pendent of the lifting and towing equipment. (6) Verify that steering components are in good • Do not allow towing equipment to contact the condition.disabled vehicle’s fuel tank. (7) Shift the transmission to NEUTRAL. • Do not allow anyone under the disabled vehiclewhile it is lifted by the towing device.
  10. 10. 0 - 10 LUBRICATION AND MAINTENANCE XJSERVICE PROCEDURES (Continued)TOWING-REAR END LIFTED (WHEEL LIFT) TOWING-FRONT END LIFTED (1) Raise front of vehicle off ground and install tow Chrysler corporation recommends that when tow-dollies under front wheels. ing with the front end lifted, a SAE approved wheel (2) Attach wheel lift to rear wheels. lift device be used. (3) Place transmission in neutral. (1) Raise the rear of the vehicle off the ground and (4) Raise vehicle to towing height. install tow dollies under rear wheels. (5) Place transmission in park (automatic trans- (2) Attach wheel lift to front wheels.mission) or first gear (manual transmission). (3) Place transmission in neutral. (4) Raise vehicle to towing height.TOWING-FRONT END LIFTED (5) Place transmission in park (automatic trans- Chrysler corporation recommends that when tow- mission) or first gear (manual transmission).ing with the front end lifted, a SAE approved wheellift device be used. FLAT SURFACE TOWING 2WD-AUTOMATIC TRANSMISSION: Provided Tow a vehicle in this manner only when all fourthe transmission is operable, tow only in NEUTRAL wheels will freely rotate.at speeds not to exceed 30 mph (50 km/h) and dis-tances less than 15 miles (25 km/h). If the vehicle is 2WD VEHICLESto be towed more than 15 miles, the propeller shaft (1) Mark the drive shaft and the axle drive pinionshould be disconnected or place tow dollies under gear shaft yoke for installation alignment reference.rear wheels. (2) Remove the drive shaft. Install a protective 2WD-MANUAL TRANSMISSION: To reduce the covering over the drive shaft U-joints to retain thempossible damage of transmission components, the assembled and protected.propeller shaft must be removed or place tow dollies (3) Cover the open end of the transmission exten-under the rear wheels before towing. Refer to Propel- sion housing.ler Shafts, Group 16 for proper removal procedure. 4WD VEHICLESFOUR-WHEEL-DRIVE VEHICLE TOWING (1) Shift transfer case lever to NEUTRAL. Chrysler Corporation recommends that a 4WD (2) Place ignition switch in the unlocked position.vehicle be transported on a flat bed device. A wheellift or sling type device can be used provided all EMERGENCY TOW HOOKSwheels are lifted off the ground using tow dollies. If the vehicle is equipped with a factory installed WARNING: REMAIN AT A SAFE DISTANCE FROM Atrailer tow package, use a SAE approved wheel lift VEHICLE THAT IS BEING TOWED VIA ITS TOWdevice. HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY.TOWING-REAR END LIFTED (SLING TYPE) (1) Raise front of vehicle off ground and install tow Some Jeep vehicles are equipped with front anddollies under front wheels. rear emergency tow hooks. The tow hooks should be (2) Attach J-hooks around rear axle shaft tube out- used for EMERGENCY purposes only.board of shock absorber. CAUTION: DO NOT use emergency tow hooks for (3) Place sling crossbar under and forward of tow truck hook-up or highway towing.bumper. (4) Attach safety chains around frame rails. (5) Turn ignition switch to OFF position to unlock HOISTING RECOMMENDATIONSsteering wheel. Refer to the Owner’s Manual for emergency vehicle (6) Secure steering wheel in the straight ahead lifting procedures.position with a clamp device designed for towing. (7) Shift transfer case to neutral. FLOOR JACK When properly positioned, a floor jack can be usedTOWING-REAR END LIFTED (WHEEL LIFT) to lift a Jeep vehicle (Fig. 3) and (Fig. 4). Support the (1) Raise front of vehicle off ground and install tow vehicle in the raised position with jack stands at thedollies under front wheels. front and rear ends of the frame rails. (2) Attach wheel lift to rear wheels. (3) Place transmission in neutral. CAUTION: Do not attempt to lift a Jeep vehicle (4) Raise vehicle to towing height. with a floor jack positioned under: (5) Place transmission in park (automatic trans-mission) or first gear (manual transmission). • An axle tube.
  11. 11. FRAME CONTACT DRIVE-ON HOIST HOIST TWIN POST CHASSIS HOIST FLOOR JACK SUB-FRAME RAIL LOCATION SUB-FRAME RAIL LOCA- TIONXJ LUBRICATION AND MAINTENANCE 0 - 11SERVICE PROCEDURES (Continued) Fig. 3 Vehicle Lifting Locations Fig. 4 Correct Vehicle Lifting Locations • A body side sill. NOTE: When a frame-contact type hoist is used, • A steering linkage component. verify that the lifting pads are positioned properly. • A drive shaft. • The engine or transmission oil pan. • The fuel tank. WARNING: THE HOISTING AND JACK LIFTING • A front suspension arm. POINTS PROVIDED ARE FOR A COMPLETE VEHI- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-NOTE: Use the correct sub-frame rail or frame rail NENT IS REMOVED FROM A VEHICLE, THElifting locations only. CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTINGHOIST DEVICE WHEN THESE CONDITIONS EXIST. A vehicle can be lifted with: • A single-post, frame-contact hoist. • A twin-post, chassis hoist. • A ramp-type, drive-on hoist.
  12. 12. XJ LUBRICATION AND MAINTENANCE 0-1 LUBRICATION AND MAINTENANCE CONTENTS page pageGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION INDEX page pageSPECIFICATIONS FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE OIL—DIESEL ENGINES . . . . . . . . . . . . 1SPECIFICATIONS MANUAL TRANSMISSION Recommended lubricant for AX15 transmissions isENGINE OIL—DIESEL ENGINES Mopar௡ 75W–90, API Grade GL–3 gear lubricant, or Use only Diesel Engine Oil meeting standard MIL- equivalent.2104C or API Classification SG/CD or CCMC PD2 . Correct lubricant level is from the bottom edge, to no more than 6 mm (1/4 in.) below the bottom edge ofSAE VISCOSITY GRADE the fill plug hole. Approximate dry fill lubricant capacity is:CAUTION: Low viscosity oils must have the proper • 3.10 liters (3.27 qts.) for 4–wheel drive applica-API quality or the CCMC G5 designation. tions. • 3.15 liters (3.32 qts.) for 2–wheel drive applica- To assure of properly formulated engine oils, it is tions.recommended that SAE Grade 15W-40 engine oilsthat meet Chrysler material standard MS-6395, be TRANSFER CASEused. European Grade 10W-40 oils are also accept-able. COMMAND-TRAC 231 . . . . . . . . . . . . . . . . . . 1.3 L Oils of the SAE 5W-30 or 10W-30 grade numberare preferred when minimum temperatures consis- FRONT AXLEtently fall below -12°C. Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 LFLUID CAPACITIES REAR AXLEFUEL TANK Model 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L* 8-1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L**Diesel Engine Equipped Vehicles . . . . . . . . . . 76.4 L * When equipped with TRAC-LOK, include 4ENGINE OIL ounces of Friction Modifier Additive. ** When equipped with TRAC-LOK, include 52.5L Diesel Engine (includes filter) . . . . . . . . . 6.5 L ounces of Friction Modifier Additive.COOLING SYSTEM2.5L Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L
  13. 13. 0-2 LUBRICATION AND MAINTENANCE XJ MAINTENANCE SCHEDULE INDEX page pageGENERAL INFORMATION SCHEDULE—A ......................... 2 MAINTENANCE SCHEDULE—DIESEL ENGINE . 2 SCHEDULE—B ......................... 3GENERAL INFORMATION SCHEDULE—AMAINTENANCE SCHEDULE—DIESEL ENGINE 1 000 KM The following are engine related Maintenance • Change engine oil.items which are unique to Diesel engine-equipped • Change engine oil filter.vehicles. Refer to the 1997 XJ Service Manual for • Check all fluid levels.gasoline engine and non-engine related Maintenance • Check correct torque, intake manifold mountingSchedules nuts. The service intervals are based on odometer read- • Check correct torque, exhaust manifold mount-ings in kilometers. There are two maintenance sched- ing nuts.ules that show proper service intervals. Use the • Check correct torque, turbocharger mountingschedule that best describes the conditions the vehi- nuts.cle is operated under. Schedule-A lists all the sched- • Check correct torque, water manifold bolts.uled maintenance to be performed under normaloperating conditions. Schedule-B is the schedule for 10 000 KMvehicles that are operated under one or more of the • Change engine oil.following conditions: • Change engine oil filter. • Day and night temperatures are below freezing. • Stop and go driving. 20 000 KM • Long periods of engine idling. • Change engine oil. • Driving in dusty conditions. • Change engine oil filter. • Short trips of less than 8 kilometers (5 miles). • Replace air filter element. • Operation at sustained high speeds during hot • Check drive belt tension.weather above 32°C (90°F). • Check glow plug operation. • Taxi, police or delivery service. • Retorque cylinder head bolts.* • Trailer towing. * Engines equipped with a steel head gasket do not need this service procedure performed. Refer toAT EACH STOP FOR FUEL OR SCHEDULED Group 9, Engines for head gasket identification.SERVICE STOP • Check engine oil level. 30 000 KM • Check engine coolant level. • Change engine oil. • Inspect drive belt. • Change engine oil filter. • Visually inspect intercooler for obstruction.Clean as necessary. 40 000 KM • Visually inspect radiator for obstruction. Clean • Change engine oil.as necessary. • Change engine oil filter. • Inspect for fuel, oil or coolant leaks. • Replace air filter element. • Inspect battery cable connection and excessive • Check drive belt tension.corrosion. • Check glow plug operation. • Inspect for presence of water in fuel filter/water • Replace fuel filter/water separator element.**separator, drain if necessary. 50 000 KM • Change engine oil. • Change engine oil filter.
  14. 14. XJ LUBRICATION AND MAINTENANCE 0-3GENERAL INFORMATION (Continued)60 000 KM SCHEDULE—B • Change engine oil. • Change engine oil filter. 500 KM • Replace air filter element. • Check correct torque, intake manifold mounting • Check glow plug operation. nuts. • Replace drive belt. • Check correct torque, exhaust manifold mount- • Check engine smoke. ing nuts. • Replace engine coolant. • Check correct torque, turbocharger mounting nuts.70 000 KM • Check correct torque, water manifold bolts. • Change engine oil. • Change engine oil filter. 1 000 KM • Change engine oil.80 000 KM • Change engine oil filter. • Change engine oil. • Check all fluid levels. • Change engine oil filter. • Replace air filter element. 5 000 KM • Check drive belt tension. • Change engine oil. • Check glow plug operation. • Change engine oil filter. • Replace fuel filter/water separator element.** 10 000 KM90 000 KM • Change engine oil. • Change engine oil. • Change engine oil filter. • Change engine oil filter. • Replace air filter element. • Check drive belt tension.100 000 KM • Check glow plug operation. • Change engine oil. • Change engine oil filter. 15 000 KM • Replace air filter element. • Change engine oil. • Check drive belt tension. • Change engine oil filter. • Check glow plug operation. 20 000 KMEVERY 40 000 KM AFTER 80 000 KM • Change engine oil. • Replace fuel filter/water separator element.** • Change engine oil filter. **The fuel filter/water separator element should be • Replace air filter element.replaced once a year if the vehicle is driven less than • Check drive belt tension.40 000 km annually or if power loss from fuel star- • Check glow plug operation.vation is detected. • Retorque cylinder head bolts.* * Engines equipped with a steel head gasket do notEVERY 10 000 KM AFTER 100 000 KM need this service procedure performed. Refer to • Change engine oil. Group 9, Engines for head gasket identification. • Change engine oil filter. 25 000 KMEVERY 20 000 KM AFTER 100 000 KM • Change engine oil. • Change engine oil. • Change engine oil filter. • Change engine oil filter. • Replace air filter element. 30 000 KM • Check drive belt tension. • Change engine oil. • Check glow plug operation. • Change engine oil filter. • Replace air filter element. • Check glow plug operation. • Replace drive belt. • Check engine smoke. • Replace engine coolant.
  15. 15. 0-4 LUBRICATION AND MAINTENANCE XJGENERAL INFORMATION (Continued)35 000 KM 80 000 KM • Change engine oil. • Change engine oil. • Change engine oil filter. • Change engine oil filter. • Replace air filter element.40 000 KM • Check glow plug operation. • Change engine oil. • Replace drive belt. • Change engine oil filter. • Check engine smoke. • Replace air filter element. • Replace engine coolant. • Check drive belt tension. • Check glow plug operation. 85 000 KM • Replace fuel filter/water separator element. • Change engine oil. • Change engine oil filter.45 000 KM • Change engine oil. 90 000 KM • Change engine oil filter. • Change engine oil. • Change engine oil filter.50 000 KM • Replace air filter element. • Change engine oil. • Check drive belt tension. • Change engine oil filter. • Check glow plug operation. • Replace air filter element. • Check drive belt tension. 95 000 KM • Check glow plug operation. • Change engine oil. • Change engine oil filter.55 000 KM • Change engine oil. 100 000 KM • Change engine oil filter. • Change engine oil. • Change engine oil filter.60 000 KM • Replace air filter element. • Change engine oil. • Check drive belt tension. • Change engine oil filter. • Check glow plug operation. • Replace air filter element. • Replace fuel filter/water separator element. • Check drive belt tension. • Check glow plug operation. EVERY 5 000 KM AFTER 100 000 KM • Replace fuel filter/water separator element. • Change engine oil. • Change engine oil filter.65 000 KM • Change engine oil. EVERY 10 000 KM AFTER 100 000 KM • Change engine oil filter. • Change engine oil. • Change engine oil filter.70 000 KM • Replace air filter element. • Change engine oil. • Check drive belt tension. • Change engine oil filter. • Check glow plug operation. • Replace air filter element. • Check drive belt tension. EVERY 20 000 KM AFTER 100 000 KM • Check glow plug operation. • Replace fuel filter/water separator element.75 000 KM • Change engine oil. • Change engine oil filter.

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