This document provides lubrication and maintenance information for diesel engines, including: - Specifications for engine oil type and viscosity grades for different temperature ranges. - Fluid capacities for fuel, engine oil, cooling system, manual transmission, transfer case, front and rear axles. - Two maintenance schedules - Schedule A for normal operating conditions, and Schedule B for vehicles operated in dust, short trips or extreme temperatures, with more frequent oil changes in Schedule B. - Maintenance items to check or replace at specific mileage intervals up to 90,000 km, including engine oil, filter, drive belt, coolant, fuel filter, and air filter changes.

1. XJ LUBRICATION AND MAINTENANCE 0-1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INDEX
page page
SPECIFICATIONS FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE OIL—DIESEL ENGINES . . . . . . . . . . . . 1
SPECIFICATIONS MANUAL TRANSMISSION
Recommended lubricant for AX15 transmissions is
ENGINE 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 of
SAE 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 oils
that meet Chrysler material standard MS-6395, be TRANSFER CASE
used. 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 number
are preferred when minimum temperatures consis- FRONT AXLE
tently fall below -12°C.
Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 L
FLUID CAPACITIES REAR AXLE
FUEL 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 4
ENGINE OIL
ounces of Friction Modifier Additive.
** When equipped with TRAC-LOK, include 5
2.5L Diesel Engine (includes filter) . . . . . . . . . 6.5 L
ounces of Friction Modifier Additive.
COOLING SYSTEM
2.5L Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L

2. 0-2 LUBRICATION AND MAINTENANCE XJ
MAINTENANCE SCHEDULE
INDEX
page page
GENERAL INFORMATION SCHEDULE—A ......................... 2
MAINTENANCE SCHEDULE—DIESEL ENGINE . 2 SCHEDULE—B ......................... 3
GENERAL INFORMATION SCHEDULE—A
MAINTENANCE 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 mounting
Schedules 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 mounting
schedule 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 normal
operating conditions. Schedule-B is the schedule for 10 000 KM
vehicles 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 to
AT 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.

3. XJ LUBRICATION AND MAINTENANCE 0-3
GENERAL 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 KM
90 000 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 KM
EVERY 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 not
EVERY 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 KM
EVERY 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.

4. 0-4 LUBRICATION AND MAINTENANCE XJ
GENERAL 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.