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Jeep Cherokee Service Manual

Older xj and yj repair, maintenance, and operation guide

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GROUP TAB LOCATOR

Introduction

0

Lubrication and Maintenance

2

Front Suspension and Axle

3

Rear Suspension and Axles

5

Brakes

6

Clutch

7

Cooling System

8

Electrical

9

Engines

11

Exhaust System and Intake Manifold

13

Frame and Bumpers

14

Fuel System

16

Propeller Shafts

19

Steering

21

Transmission and Transfer Cases

22

Wheels and Tires

23

Body Components

24

Heating and Air Conditioning

25

Emission Control Systems

Index

Service Manual Comment Forms

(Rear of Manual)

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Summary of Contents for Jeep Cherokee

Page 1 GROUP TAB LOCATOR Introduction Lubrication and Maintenance Front Suspension and Axle Rear Suspension and Axles Brakes Clutch Cooling System Electrical Engines Exhaust System and Intake Manifold Frame and Bumpers Fuel System Propeller Shafts Steering Transmission and Transfer Cases Wheels and Tires Body Components Heating and Air Conditioning Emission Control Systems...
Page 3: Table Of Contents
VEHICLE DESIGNATIONS VEHICLE CODE DESIGNATIONS The Vehicle Code Designations chart lists the vehi- cle description and code for Cherokee and Wrangler vehicles. The codes are used to identify vehicle types in charts, captions and in service procedures. The ve- hicle codes are different than the Vehicle Identifica- tion Number (VIN) or the wheelbase/model code.
Page 4 INTRODUCTION...
Page 5 INTRODUCTION...
Page 6 A vehicle safety certification label (Fig. 1) is at- data concerning the vehicle. Refer to the VIN decod- tached to every Jeep vehicle. The label certifies that ing chart to determine the identification of a vehicle. the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards.
Page 7: Engine And Transmission/Transfer Case Identification
VEHICLE DIMENSION DATA The vehicle dimension data charts list the exterior and interior dimensions for each type of Jeep vehicle. VEHICLE LOAD DATA The Vehicle Load Data chart lists the following in- formation: •...
Page 8 INTRODUCTION VEHICLE DIMENSION DATA...
Page 9 INTRODUCTION VEHICLE LOAD DATA—XJ...
Page 10 INTRODUCTION VEHICLE LOAD DATA—YJ...
Page 11 INTRODUCTION TRAILER TOWING SPECIFICATIONS...
Page 12 INTRODUCTION VEHICLE CONTROL AND DISPLAY SYMBOLS...
Page 13 INTRODUCTION MEASUREMENT AND TORQUE SPECIFICATIONS INDEX page page Metric and English/Sae Conversion ... . 11 Torque Specifications ..... . 11 Specification Notations .
Page 14 INTRODUCTION TORQUE SPECIFICATIONS...
Page 15 INTRODUCTION imprinted with a single-digit strength class on the THREAD NOTATION—SAE AND METRIC nut face. Refer to the bolt identification and bolt strength chart. METRIC CONVERSION Refer to the chart to convert torque values listed in metric Newton-meters (N m). Also, use the chart to convert between millimeters (mm) and inches (in.) the greater the bolt strength.
Page 16 INTRODUCTION BOLT IDENTIFICATION...
Page 17 INTRODUCTION BOLT STRENGTH...
Page 18 INTRODUCTION METRIC CONVERSION...
Page 19 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page CHASSIS AND BODY COMPONENTS ..28 GENERAL INFORMATION ....1 DRIVETRAIN .
Page 20 Fig. 3 NLGI Lubricant Container Certification/ Identification Symbol LUBRICATION AND REPLACEMENT PARTS RECOMMENDATION Jeep vehicles are engineered to provide many years of dependable operation. However, lubrication service and maintenance are required for each vehicle. When necessary, MOPAR brand lubricants and genuine re- placement parts are highly recommended.
Page 21 LUBRICATION AND MAINTENANCE 0 - 3 FLUID CAPACITIES an auxiliary cooler, these figures may vary. Refer to Group 21, Transmission for proper fluid fill proce- Fuel Tank dure. XJ .............76.4 L (20.2 gal.) Manual Transmission YJ(Standard) ........56.8 L (15 gal.) YJ(Optional) ........75.7 L (20 gal.) AX4/5 (4X2) .........3.3 L (3.5 qts.) Engine Oil...
Page 22 There are two maintenance schedules that show spected. Examine threaded fasteners for looseness. proper service intervals for Jeep Cherokee and Jeep Wrangler vehicles. Use the schedule that best de- HARSH SURFACE ENVIRONMENTS scribes the conditions the vehicle is operated under.
Page 23 LUBRICATION AND MAINTENANCE 0 - 5 • Flush and replace engine coolant if it has been 37,500 MILES (60 000 KM) OR AT 30 MONTHS • Change engine oil. 30,000 miles (48 000 km) or 24 months since last • Replace engine oil filter. change.
Page 24 0 - 6 LUBRICATION AND MAINTENANCE • Adjust drive belts. SCHEDULE—B • Drain and refill transfer case fluid. 3,000 MILES (4 800KM) • Change engine oil. 33,000 MILES (53 000KM) • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. 6,000 MILES (9 600KM) •...
Page 25 LUBRICATION AND MAINTENANCE 0 - 7 • Drain and refill automatic transmission fluid. 90,000 MILES (144 000KM) • Change front and rear axle fluid.* • Change engine oil. • Replace air cleaner element. • Replace engine oil filter. • Replace distributor cap and rotor. •...
Page 26 0 - 8 LUBRICATION AND MAINTENANCE • Drain and refill transfer case fluid. 120,000 MILES (192 000KM) • Change engine oil. NOTE 1: Not required for California vehicles, rec- • Replace engine oil filter. ommended for proper vehicle performance. • Lubricate steering linkage. * Off-highway operation, trailer towing, taxi, limou- •...
Page 27 LUBRICATION AND MAINTENANCE 0 - 9 JUMP STARTING, TOWING AND HOISTING INDEX page page Four-Wheel-Drive Vehicle Towing ... . . 12 Towing Recommendations ....10 Ground Clearance and Ramp Angle .
Page 28 When properly positioned, a floor jack can be used NENT IS REMOVED FROM A VEHICLE, THE to lift a Jeep vehicle (Fig. 2 and 3). Support the ve- CENTER OF GRAVITY IS ALTERED MAKING SOME hicle in the raised position with jack stands at the HOISTING CONDITIONS UNSTABLE.
Page 29 LUBRICATION AND MAINTENANCE 0 - 11 • Do not tow a vehicle in a manner that could jeop- ardize the safety of the operator, pedestrians or other motorists. • Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole.
Page 30 0 - 12 LUBRICATION AND MAINTENANCE TOWING-FRONT END LIFTED (SLING-TYPE) TOWING-REAR END LIFTED (SLING-TYPE) CAUTION: Many vehicles are equipped with air 4WD XJ VEHICLES dams, spoilers, and/or ground effect panels. To (1) Raise the front of the vehicle off the ground avoid component damage, a wheel-lift towing vehi- and install tow dollies under front wheels.
Page 31 2WD VEHICLES AND CAUSE SERIOUS INJURY. (1) Mark the drive shaft and the axle drive pinion Some Jeep vehicles are equipped with front and gear shaft yoke for installation alignment reference. rear emergency tow hooks (Fig. 9). The tow hooks (2) Remove the drive shaft.
Page 32 0 - 14 LUBRICATION AND MAINTENANCE (3) Cover the open end of the transmission exten- (3) Shift transmission to Neutral. sion housing. (4) Turn off engine with the ignition key in the un- locked OFF position. 4WD VEHICLES—XJ (5) Shift transfer case lever from 2H to N (NEU- (1) Shift transfer case lever to NEUTRAL.
Page 33 LUBRICATION AND MAINTENANCE 0 - 15 ENGINE MAINTENANCE INDEX page page Accessory Drive Belt ..... . . 21 Engine Oil Change and Filter Replacement ..16 Air Cleaner Element .
Page 34 0 - 16 LUBRICATION AND MAINTENANCE CONTAINER IDENTIFICATION CRANKCASE OIL LEVEL INSPECTION Standard engine oil identification notations have CAUTION: Do not overfill crankcase with engine oil, been adopted to aid in the proper selection of engine oil foaming and oil pressure loss can result. oil.
Page 35 (3) Add oil, verify crankcase oil level and start en- All Jeep engines are equipped with a high quality gine. Inspect for oil leaks. full-flow, throw-away type oil filter. Chrysler Corpo- ration recommends a Mopar or equivalent oil filter be used.
Page 36 0 - 18 LUBRICATION AND MAINTENANCE be at least above the ADD mark and preferably at USED ENGINE OIL DISPOSAL Care should be exercised when disposing used en- the FULL mark. Add coolant to the coolant recovery gine oil after it has been drained from a vehicle en- bottle only, if necessary.
Page 37 LUBRICATION AND MAINTENANCE 0 - 19 CRANKCASE VENTILATION SYSTEM All Jeep 2.5L and 4.0L engines are equipped with a crankcase ventilation (CCV) system. Refer to Group 25 Emissions, for additional information. FUEL FILTER The fuel filter requires service only when a fuel contamination problem is suspected.
Page 38 0 - 20 LUBRICATION AND MAINTENANCE line. You may encounter fuels containing 3 percent or DLING/SERVICING A BATTERY. BATTERY more methanol along with other alcohols called cosol- ELECTROLYTE CONTAINS SULFURIC ACID AND vents. WILL CAUSE HARM IF IT CONTACTS SKIN, EYES Problems that are the result of using methanol/gas- OR CLOTHING.
Page 39 LUBRICATION AND MAINTENANCE 0 - 21 ENGINE SUPPORTS (2) Inspect the rubber in the engine support cush- ions for softening and swelling. Slight surface deteri- The general condition of the engine supports oration and wear at the ends will not affect the should be inspected when engine compartment or un- functioning of an engine support.
Page 40 LUBRICANT SPECIFICATION When it becomes necessary to add to or change the lube oil in a Jeep manual transmission, use SAE Fig. 1 Clutch Reservoir Location—Typical 75W-90, API Quality Grade GL-5 gear lubricant. The fluid level is determined by its height in rela- LUBRICANT LEVEL tion to the level indicator ring (Fig.
Page 41 LUBRICATION AND MAINTENANCE 0 - 23 other under hood service is performed. Refer to Group 21, Transmission for proper service proce- dures. CAUTION: To minimize fluid contamination, verify that dipstick is seated in the fill tube after fluid level reading is taken. TO INSPECT THE TRANSMISSION FLUID LEVEL WARNING: USE EXTREME CAUTION WHEN THE...
Page 42 Fig. 4 Dipstick & ATF Level SPECIAL ADDITIVES FLUID DRAIN AND REFILL The addition of any special-type fluid to a Jeep au- The Transfer Case should be serviced as specified tomatic transmission is not recommended. The only in the Lubrication and Maintenance Schedules.
Page 43 (9) Remove the fill-hole plug and add the replace- When it becomes necessary to change the axle lu- ment gear lubricant to the differential housing. Refer bricant in a Jeep front or rear axle, use the following to Specifications above. procedure.
Page 44 0 - 26 LUBRICATION AND MAINTENANCE LUBRICANT SPECIFICATION Use Mopar, Multi-purpose Grease or any lubricate that is identified as NLGI GC-LB lubricant. RUBBER AND PLASTIC HOSES/TUBING The condition of underbody rubber hose and plastic tubing should be inspected whenever underbody ser- vice is performed.
Page 45 LUBRICATION AND MAINTENANCE 0 - 27 Fig. 15 Rear Axle Vent Hose—YJ Vehicles Fig. 12 Front Axle Vacuum Shift Tubing Fig. 13 Transfer Case Vent Hose (4WD)—Typical Fig. 16 Rear Axle Vent Hose At Wheelhouse—YJ Vehicles Fig. 14 Rear Axle Vent Hose—XJ Vehicles...
Page 46 CHASSIS COMPONENT AND WHEEL BEARING LUBRICANTS The chassis component and wheel bearing lubri- cants that are recommended for Jeep vehicles are identified by the NLGI Certification Symbol (Fig. 1). The symbol contains a coded designation that identi- fies the usage and quality of the lubricant.
Page 47 LUBRICATION AND MAINTENANCE 0 - 29 hose unless the caliper must also be removed (14) Tighten the spindle nut with 28 N m (21 ft. for maintenance.Support the caliper with a lbs.) torque while rotating the disc brake rotor to hanger to prevent brake fluid hose damage.
Page 48 (Fig. 6). The fluid level in the res- FLUID SPECIFICATION ervoir can be determined with the fluid either hot or Jeep power brake systems require MOPAR Heavy- cold. Duty Brake Fluid, or an equivalent product identified as conforming to FMVSS No. 116, DOT-3 and SAE J-1703 specifications.
Page 49 LUBRICATION AND MAINTENANCE 0 - 31 BRAKE SYSTEM INSPECTION A brake system inspection should be included with all brake service procedures, and also each time the vehicle is lubricated. (1) Inspect the brake pads and linings for excessive wear, cracks, charred surfaces and broken rivets. (2) Inspect brake pads and linings for contamina- tion from brake fluid, and/or other fluids.
Page 50 Group 22, Tires And Wheels. ROTATION Refer to Group 22, Tires And Wheels for the recom- mended method of tire/wheel rotation for a Jeep ve- hicle. BODY COMPONENTS LUBRICATION REQUIREMENTS All Jeep operating mechanisms and linkages should be lubricated when necessary.
Page 51 LUBRICATION AND MAINTENANCE 0 - 33 BODY LUBRICANT SPECIFICATIONS HEADLAMPS MAINTENANCE SCHEDULE Every six months check the headlamp beams to en- sure that the headlamp beams are correctly posi- tioned. AIM ADJUSTMENT Refer to Group 8L, Lamps for headlamp aim ad- justment procedures.
Page 53 FRONT SUSPENSION AND AXLE 2 - 1 FRONT SUSPENSION AND AXLE CONTENTS page page AXLE NOISE/VIBRATION DIAGNOSIS ..18 MODEL 30 AXLE AND TUBE AXLE (2WD) ..22 AXLE SPECIFICATIONS ....49 TORQUE SPECIFICATIONS .
Page 54 2 - 2 FRONT SUSPENSION AND AXLE the opposite wheel. Wheels are attached to a hub/ bearings which bolts to the knuckles. The hub/bear- ing is not serviceable and is replaced as a unit. Steering knuckles pivot on replaceable ball studs at- tached to the axle tube yokes.
Page 55 FRONT SUSPENSION AND AXLE 2 - 3 spring and axle travel (jounce or rebound) is limited through use of rubber bumpers mounted on the frame. Suspension components which use rubber bushings should be tightened at vehicle ride height. This will prevent premature failure of the bushing and main- tain ride comfort.
Page 56 2 - 4 FRONT SUSPENSION AND AXLE tions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed. Fig. 6 Differential Operation—Straight-Ahead Driving the axle shafts to turn at unequal speeds (Fig. 7). In this instance, the input torque applied to the pinion gears is not divided equally.
Page 57: Front Wheel Alignment
FRONT SUSPENSION AND AXLE 2 - 5 FRONT WHEEL ALIGNMENT INDEX page page Alignment Measurements and Adjustments ..8 Pre-Alignment Inspection ....6 General Information .
Page 58 2 - 6 FRONT SUSPENSION AND AXLE even tire wear. The wheel toe position is the final (1) Tires with the same recommended air pressure, front wheel alignment adjustment. size, and thread wear. Refer to Group 22, Tires And • STEERING AXIS INCLINATION ANGLE is mea- Wheels for diagnosis information.
Page 59 FRONT SUSPENSION AND AXLE 2 - 7 SUSPENSION AND STEERING SYSTEM DIAGNOSIS...
Page 60 2 - 8 FRONT SUSPENSION AND AXLE Fig. 2 Adjustment—YJ Vehicles ALIGNMENT MEASUREMENTS AND ADJUSTMENTS Before each alignment reading, the vehicle should be jounced (rear first, then front). Grasp each Fig. 3 Adjustment—XJ Vehicles bumper at the center and jounce the vehicle up and does not return toward the center position unas- down several times.
Page 61 FRONT SUSPENSION AND AXLE 2 - 9 Fig. 5 Steering Linkage—XJ (RHD) wheels. Secure the steering wheel with the front (4) Adjust the left wheel toe position with the tie wheels in the straight-ahead position. Turn off the rod. Turn the sleeve until the left wheel is at specifi- engine.
Page 62 2 - 10 FRONT SUSPENSION AND AXLE Fig. 7 Steering Linkage YJ Vehicles TOE POSITION—YJ VEHICLES The tie rod and adjustment sleeve have both The wheel toe position should be the final front right and left hand threads to provide equal ad- wheel alignment adjustment.
Page 63 FRONT SUSPENSION AND AXLE 2 - 11 XJ FRONT SUSPENSION INDEX page page Axle Bushing Replacement ....12 Spring and Shock Diagnosis ....13 Coil Spring .
Page 64 2 - 12 FRONT SUSPENSION AND AXLE Fig. 2 Stabilizer Bar Fig. 3 Upper and Lower Suspension Arms (3) Tighten the stabilizer bar to connecting link nut to 36 N m (27 ft. lbs.) torque. (4) Remove the supports and lower the vehicle. UPPER SUSPENSION ARM REMOVAL (1) Raise and support the vehicle.
Page 65 FRONT SUSPENSION AND AXLE 2 - 13 INSTALLATION (1) Position the lower suspension arm at the axle bracket and rear bracket (Fig. 3). (2) Install the bolts and finger tighten the nuts (Fig. 3). (3) Remove support and lower the vehicle. (4) Tighten the front and rear nuts to 115 N m (85 ft.
Page 66 2 - 14 FRONT SUSPENSION AND AXLE (7) Disconnect the drag link from the pitman arm. INSTALLATION (1) Position the lower retainer and grommet on the (8) Lower the axle until the spring is free from the upper stud. Insert the shock absorber through the upper mount.
Page 67 FRONT SUSPENSION AND AXLE 2 - 15 YJ FRONT SUSPENSION INDEX page page Leaf Spring ......16 Spring and Shock Diagnosis .
Page 68 2 - 16 FRONT SUSPENSION AND AXLE Fig. 3 Spring & Shock Absorber Fig. 2 Stabilizer Bar LEAF SPRING The shock absorber bushings do not require any type of lubrication. Do not lubricate the bushings to REMOVAL reduce bushing noise. Grease or mineral oil-base lu- (1) Raise the vehicle.
Page 69 FRONT SUSPENSION AND AXLE 2 - 17 (6) Remove the support stands and lower the vehi- cle. (7) Tighten the front shackle plate nut (Fig. 3) to 135 N m (100 ft. lbs.) torque. (8) Tighten the rear eye bracket nut to 142 N m (105 ft.
Page 70 2 - 18 FRONT SUSPENSION AND AXLE AXLE NOISE/VIBRATION DIAGNOSIS INDEX page page Driveline Snap ......19 Low Speed Knock .
Page 71 FRONT SUSPENSION AND AXLE 2 - 19 • Bent axle shaft Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes Check for loose or damaged front-end components when the bearings are loaded. Road test the vehicle. or engine/transmission mounts.
Page 72 2 - 20 FRONT SUSPENSION AND AXLE SERVICE DIAGNOSIS...
Page 73 FRONT SUSPENSION AND AXLE 2 - 21 SERVICE DIAGNOSIS (CONT’D)
Page 74 2 - 22 FRONT SUSPENSION AND AXLE MODEL 30 AXLE AND TUBE AXLE (2WD) INDEX page page Axle Bushing Replacement ....34 Final Assembly ......46 Axle Shaft—Cardan U-Joint .
Page 75 FRONT SUSPENSION AND AXLE 2 - 23 DRIVE AXLE ASSEMBLY REPLACEMENT—XJ CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible VEHICLES premature axle failure. REMOVAL (1) Raise the vehicle and position support stands LUBRICANT CHANGE under the frame rails behind the lower suspension The gear lubricant will drain quicker if the vehicle arm frame brackets.
Page 76 2 - 24 FRONT SUSPENSION AND AXLE (6) Install the shock absorber and tighten the bolt (12) Loosen BUT DO NOT REMOVE the bolts that to 23 N m (17 ft. lbs.) torque. attach the spring rear pivot at the frame rail brack- (7) Install the stabilizer bar link to the axle ets.
Page 77 FRONT SUSPENSION AND AXLE 2 - 25 (17) Tighten the track bar nut at the axle bracket INSTALLATION to 100 N m (74 ft. lbs.) torque. (1) Apply a light coating of gear lubricant on the (18) Check the front wheel alignment. lip of pinion seal.
Page 78 2 - 26 FRONT SUSPENSION AND AXLE Fig. 6 Hub, Knuckle and Axle Shaft INSTALLATION (1) Thoroughly clean the axle shaft (Fig. 6) and ap- ply a thin film of Mopar Wheel Bearing Grease to the shaft splines, seal contact surface, hub bore. (2) Install the axle shaft into the housing and dif- ferential side gears.
Page 79 FRONT SUSPENSION AND AXLE 2 - 27 VACUUM DISCONNECT AXLE—YJ VEHICLES VACUUM CONTROL SYSTEM The disconnect axle control system consists of; • Vacuum control switch on the transfer case • Air vent filter • Shift motor • Indicator switch • Vacuum switch •...
Page 80 2 - 28 FRONT SUSPENSION AND AXLE Fig. 10 Vacuum Hose Routing...
Page 81 FRONT SUSPENSION AND AXLE 2 - 29 DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS...
Page 82 2 - 30 FRONT SUSPENSION AND AXLE DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT’D)
Page 83 FRONT SUSPENSION AND AXLE 2 - 31 (3) Install the E-clips on the shift motor shaft and SHIFT MOTOR—REMOVAL/DISASSEMBLY (1) Disconnect the vacuum and wiring connector housing. from the shift housing. (4) Install the shift motor housing gasket and (2) Remove indicator switch. cover.
Page 84 2 - 32 FRONT SUSPENSION AND AXLE Fig. 14 Bearing Removal Tool Installed Fig. 17 Secondary Installation of Seal (Step Two) (5) Insert the intermediate axle shaft into the dif- ferential side gear. (6) Install the shift collar on the splined end of the intermediate axle shaft.
Page 85 FRONT SUSPENSION AND AXLE 2 - 33 The lower ball stud has two different designs. For this reason installer 6752 will also be needed. Check installers for proper fit. KNUCKLE REMOVAL (1) Remove hub bearing and axle shaft refer to the Removal procedure.
Page 86 2 - 34 FRONT SUSPENSION AND AXLE Fig. 21 Lower Ball Stud Remove/Install (4) Install the Hub Bearing and Axle Shaft accord- ing to the installation procedure. (5) Reconnect the tie-rod or drag link end onto the steering knuckle arm. Install the ABS sensor wire and bracket to the knuckle, refer to Group 5 Brakes.
Page 87 FRONT SUSPENSION AND AXLE 2 - 35 Fig. 23 Spread Differential Housing Fig. 25 Axle Seal Installation (2) Install the inner axle seal on Tool 6228-1 (Fig. 26). (3) Thread the reverse side of Installer 6228-1 tightly onto the threaded rod tool (Fig. 26). (4) Press the seal into position.
Page 88 2 - 36 FRONT SUSPENSION AND AXLE Place adapter rings so they do not damage (4) Use a drift to remove the pinion gear mate the bearing cage. shaft lock pin (Fig. 29). Fig. 29 Mate Shaft Lock Pin Removal (5) Remove the mate shaft with a drift and ham- mer (Fig.
Page 89 FRONT SUSPENSION AND AXLE 2 - 37 Fig. 33 Remove Pinion Gear Fig. 31 Pinion Mate Gear Removal Fig. 32 Pinion Yoke Removal (3) Drive out pinion gear from housing with raw- hide or plastic hammer (Fig. 33). Catch the pinion with your hand to prevent it from falling and being damaged.
Page 90 2 - 38 FRONT SUSPENSION AND AXLE • Raised metal on shoulders of cup bores should be removed with a hand stone. • Wear or damage to pinion gear mate shaft, pinion gears, side gears and thrust washers. Replace as a matched set only.
Page 91 FRONT SUSPENSION AND AXLE 2 - 39 THE BUTTON END ON THE PINION GEAR HEAD IS NO LONGER A MACHINED-TO-SPECIFI- CATIONS SURFACE. DO NOT USE THIS SUR- FACE PINION DEPTH SET-UP CHECKING (Fig. 40). Fig. 40 Pinion Gear Head Fig. 38 Ring Gear Bolt Installation Compensation for depth variance is achieved by a (5) Lubricate all differential components with hy- selected thickness oil slinger (production) or shims...
Page 92 2 - 40 FRONT SUSPENSION AND AXLE PINION GEAR DEPTH VARIANCE New gear set: note the depth variance etched into both the original and the replacement pin- ion gear. Add or subtract the thickness of the original depth shims to compensate for the dif- ference in the depth variances.
Page 93 FRONT SUSPENSION AND AXLE 2 - 41 Fig. 45 Pinion Front Bearing Cup Installation (2) Install the bearing cup with Installer D-146 and Driver Handle C-4171 (Fig. 46). Ensure cup is correctly seated. Fig. 43 Differential Case End Play Measurement •...
Page 94 2 - 42 FRONT SUSPENSION AND AXLE The plunger travel, plus or minus the vari- ance etched in the gear, is the required thick- ness for the depth shims. (7) Measure the thickness of each depth shim with a micrometer. Combine the shims necessary for total required shim pack thickness.
Page 95 FRONT SUSPENSION AND AXLE 2 - 43 Fig. 53 Tightening Pinion Nut Fig. 51 Pinion Seal Installation Fig. 54 Check Pinion Gear Torque Fig. 52 Pinion Yoke Installation DIFFERENTIAL SHIM PACK MEASUREMENT AND (11) Check bearing rotating torque with an inch pound torque wrench (Fig.
Page 96 2 - 44 FRONT SUSPENSION AND AXLE Fig. 56 Shim Pack Calculations Fig. 55 Shim Pack Measurement (3) Insert a small pry bar between the bearing cap and left side of differential case. Pry the case as far as possible to right side (Fig. 55). Zero the dial indi- cator pointer.
Page 97 FRONT SUSPENSION AND AXLE 2 - 45 Fig. 58 Spread Differential Housing Fig. 60 Differential Bearing Cap Reference Letters (3) Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator (Fig. 58). (4) Remove the dial indicator.
Page 98 2 - 46 FRONT SUSPENSION AND AXLE (4) Note patterns in compound. Refer to (Fig. 63) for interpretation of contact patterns and adjust ac- cordingly. FINAL ASSEMBLY (1) Install the axle shafts. Refer to Axle Shaft In- stallation in this Group. (2) Scrape the residual sealant from the housing and cover mating surfaces.
Page 99 FRONT SUSPENSION AND AXLE 2 - 47 Fig. 63 Gear Tooth Contact Patterns...
Page 100 2 - 48 FRONT SUSPENSION AND AXLE Fig. 64 Typical Housing Cover With Sealant...
Page 101: Torque Specifications
FRONT SUSPENSION AND AXLE 2 - 49 AXLE SPECIFICATIONS MODEL 30 FRONT AXLE Side Gear Clearance .0.12-0.20mm (0.005-0.008 in.) Ring Gear Axle Type ............Hypoid Diameter ........18.09 cm (7.125 in.) Lubricant....SAE Thermally Stable 80W-90 Backlash......0-0.15 mm (0.005-0.008 in.) Lube Capacity YJ .............1.65 L (3.76 pts.) Pinion Std.
Page 103 SUSPENSION COMPONENTS to the axle brackets. All mounting points of the sta- bilizer bar are isolated by bushings. The Jeep rear suspension is comprised of; • Drive axle The track bar on the YJ is used to minimize rear • Leaf springs axle side-to-side movement.
Page 104 3 - 2 REAR SUSPENSION AND AXLES • The ring gear (bolted to the differential case) ro- tates the case • The differential pinion gears (mounted on the pin- ion mate shaft in the case) rotate the side gears • The side gears (splined to the axle shafts) rotate the shafts During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft.
Page 105 REAR SUSPENSION AND AXLES 3 - 3 XJ SUSPENSION INDEX page page Leaf Spring ....... 4 Spring and Shock Diagnosis .
Page 106 3 - 4 REAR SUSPENSION AND AXLES Fig. 1 Spring & Shock Absorber—XJ Vehicles SHOCK ABSORBER (6) Remove nuts, U-bolts and spring bracket from axle (Fig. 1). REMOVAL (7) Remove nut and bolt attaching spring front eye (1) Remove the shock absorber upper bolts from the to shackle (Fig.
Page 107 REAR SUSPENSION AND AXLES 3 - 5 LEAF SPRING EYE BUSHING REPLACEMENT STABILIZER BAR (1) Assemble tools shown (Fig. 2). Tighten the nut REMOVAL located at the socket wrench end of the threaded rod (1) Raise and support the vehicle. until the bushing is forced out.
Page 108 3 - 6 REAR SUSPENSION AND AXLES YJ SUSPENSION INDEX page page Leaf Spring ....... 7 Spring and Shock Diagnosis .
Page 109 REAR SUSPENSION AND AXLES 3 - 7 Fig. 1 Spring & Shock Absorber—YJ Vehicles SHOCK ABSORBER INSTALLATION (1) Position the spring front eye in the bracket. REMOVAL Loosely install the attaching bolt and nut (Fig. 1). Do (1) Remove the upper attaching nut and washer not tighten at this time.
Page 110 3 - 8 REAR SUSPENSION AND AXLES (2) Remove the fasteners that attach the track bar to the frame bracket and axle bracket (Fig. 3). Fig. 2 Spring Eye Bushing Removal The bushing must be centered in the spring eye. The ends of the bushing must be flush or Fig.
Page 111 REAR SUSPENSION AND AXLES 3 - 9 AXLE NOISE/VIBRATION DIAGNOSIS INDEX page page Driveline Snap ......10 Low Speed Knock .
Page 112 3 - 10 REAR SUSPENSION AND AXLES This will load the bearings and change the noise (2) Attach a one-inch long piece of masking tape at level. Where axle bearing damage is slight, the noise the center of each tire tread for use as reference marks. is usually not noticeable at speeds above 30 mph.
Page 113 REAR SUSPENSION AND AXLES 3 - 11 SERVICE DIAGNOSIS...
Page 114 3 - 12 REAR SUSPENSION AND AXLES SERVICE DIAGNOSIS (CONT’D)
Page 115 REAR SUSPENSION AND AXLES 3 - 13 MODEL 35 AXLE INDEX page page Axle Shaft ....... 16 Drive Axle Assembly Replacement—YJ Vehicles .
Page 116 3 - 14 REAR SUSPENSION AND AXLES (9) Support the axle with a hydraulic jack under the differential. (10) Remove the spring U-bolts from the plate brackets. (11) Lower the jack enough to remove the axle. INSTALLATION CAUTION: Suspension components with rubber bushings should be tightened with the vehicle at normal height.
Page 117 REAR SUSPENSION AND AXLES 3 - 15 (7) Disconnect the brake hose at the axle junction (15) Tighten the spring front pivot bolt/nut to 142 block. Do not disconnect the wheel cylinder tub- N m (105 ft. lbs.) torque. Tighten the spring shackle ing fittings.
Page 118 3 - 16 REAR SUSPENSION AND AXLES Fig. 3 Seal Removal Fig. 5 Tightening Pinion Shaft Nut (7) Continue tightening the shaft nut in small in- crements until the correct bearing preload torque is attained. (8) Align the installation reference marks and at- tach the drive shaft to the yoke.
Page 119 REAR SUSPENSION AND AXLES 3 - 17 AXLE SHAFT SEAL AND BEARING REMOVAL (1) Remove the axle shaft. Refer to the Removal procedures in this Group. (2) Remove the axle shaft seal from the end of the axle shaft tube with a small pry bar. (3) Remove the bearing if it appears damaged.
Page 120 3 - 18 REAR SUSPENSION AND AXLES Fig. 11 Spread Differential Housing Fig. 9 Axle Shaft Seal Installation (5) Separate the housing enough to remove the DIFFERENTIAL REMOVAL case from the housing. Measure the distance with the To service the differential the axle shafts must be dial indicator (Fig.
Page 121 REAR SUSPENSION AND AXLES 3 - 19 Place adapter rings so they do not damage the bearing cage. Fig. 15 Pinion Mate Gear Removal (5) Remove the case from the vise. PINION REMOVAL/DISASSEMBLY (1) Remove the pinion yoke nut and washer. Use Remover C-452 and Wrench C-3281 to remove the pinion yoke (Fig.
Page 122 3 - 20 REAR SUSPENSION AND AXLES Fig. 19 Rear Bearing Cup Removal Fig. 17 Remove Pinion Gear Fig. 20 Collapsible Spacer Fig. 18 Front Bearing Cup Removal CLEANING/INSPECTION (7) Remove the collapsible preload spacer (Fig. 20). Wash differential components with cleaning solvent (8) Remove the inner bearing from the pinion with and dry with compressed air.
Page 123 REAR SUSPENSION AND AXLES 3 - 21 plus (+) number, minus (-) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0).
Page 124 3 - 22 REAR SUSPENSION AND AXLES PINION MEASUREMENT AND ASSEMBLY PINION GEAR DEPTH MEASUREMENT Pinion gear depth measurement is necessary when; • Axle housing or differential case is replaced • Pinion select shim pack is unknown • Ring and pinion gears are replaced Measurements are taken with pinion cups and pin- ion bearings installed in housing.
Page 125 REAR SUSPENSION AND AXLES 3 - 23 (1) Assemble Pinion Gauge Set, Pinion Block and pinion bearings. Install assembly into differential pinion gear bore and hand tighten cone (Fig. 26). Fig. 28 Pinion Gear Depth Measurement total required shim pack thickness. Include oil slinger or baffle thickness with the total shim pack thickness.
Page 126 3 - 24 REAR SUSPENSION AND AXLES (2) Install the pinion front bearing cup with In- staller D-130 and Handle C-4171 (Fig. 30). Fig. 30 Pinion Front Bearing Cup Installation (3) Install pinion front bearing, oil slinger. Apply a light coating of gear lubricant on the lip of pinion seal.
Page 127 REAR SUSPENSION AND AXLES 3 - 25 Fig. 36 Check Pinion Gear Torque Fig. 34 Pinion Yoke Installation (2) Match each bearing cup with bearing (original). Install the cups on the bearings. Note:It is recommended whenever bearings are re- moved that they be replaced. (3) Install the differential case in the housing.
Page 128 3 - 26 REAR SUSPENSION AND AXLES (6) Attach a dial indicator to the housing. Position the indicator plunger so that it contacts the ring gear mating surface (Fig. 38). Fig. 39 Ring Gear Bolt Installation Fig. 38 Shim Measurement (7) Pry the differential case to one side and zero the dial indicator pointer.
Page 129 REAR SUSPENSION AND AXLES 3 - 27 Fig. 43 Ring Gear Backlash Measurement Fig. 41 Differential Installation Fig. 42 Differential Bearing Cap Reference Letters Fig. 44 Backlash Shim Adjustment BACKLASH AND CONTACT PATTERN ANALYSIS ness. It will also show if the ring gear backlash has (1) Rotate assembly several revolutions to seat been adjusted correctly.
Page 130 3 - 28 REAR SUSPENSION AND AXLES Fig. 45 Gear Tooth Contact Patterns...
Page 131 REAR SUSPENSION AND AXLES 3 - 29 FINAL ASSEMBLY (1) Install the axle shafts. Refer to Axle Shaft In- stallation within this group. (2) Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of MOPAR Sili- cone Rubber Sealant on the housing cover (Fig.
Page 132 3 - 30 REAR SUSPENSION AND AXLES 8 1/4 AXLE INDEX page page Axle Shaft, Seal and Bearing Service ..32 Lubricant Change ......31 Differential Service .
Page 133 REAR SUSPENSION AND AXLES 3 - 31 LUBRICANT SPECIFICATIONS (1) Support the axle on a hydraulic jack under the differential. Position the axle under the vehicle. Multi-purpose, hypoid gear lubricant should be (2) Raise the axle and align the spring center bolts used in the 8 1/4 inch axle.
Page 134 3 - 32 REAR SUSPENSION AND AXLES Fig. 3 Pinion Mate Shaft Lock Screw Fig. 2 Typical Housing Cover With Sealant AXLE SHAFT, SEAL AND BEARING SERVICE CAUTION: When rear axle service is necessary, both rear wheels must be raised off the surface so that they are free to rotate.
Page 135 REAR SUSPENSION AND AXLES 3 - 33 (Fig. 4). Push the axle shaft outward to seat the C- clip lock. (3) Insert the pinion gear mate shaft in the case. Install through the thrust washers and pinion gears. Align the hole in the shaft with the lock screw hole. Install the lock screw with Loctite on the threads.
Page 136 3 - 34 REAR SUSPENSION AND AXLES INSTALLATION (1) Examine the splines on the pinion shaft for burrs or wear. (2) Remove any burrs and clean the shaft. (3) Inspect the pinion yoke for cracks, worn splines and a worn seal contact surface. Repair or replace the yoke as necessary.
Page 137 REAR SUSPENSION AND AXLES 3 - 35 CAUTION: Do not subject the bearings, cups, bores or journals to heat from a torch or other abuse. Per- manent damage could result. Special tools are available and recommended when servicing axle. DIFFERENTIAL CASE REMOVAL (1) Remove the axle shafts, refer to Axle Shaft Re- moval.
Page 138 3 - 36 REAR SUSPENSION AND AXLES RING GEAR Fig. 12 Threaded Adjuster Tool Fig. 14 Inner Bearing Removal Do not remove the ring gear from case unless the runout must be measured. (1) Clamp the case with the ring gear bolts facing upward.
Page 139 REAR SUSPENSION AND AXLES 3 - 37 CLEANING/INSPECTION (1) Clean all differential components in cleaning solvent. Allow the bearings to either air dry or dry them with a lint-free cloth. Dry the other components with compressed air. (2) Examine each component for wear or damage. (3) Replace shims, bearings and cups as a set only.
Page 140 3 - 38 REAR SUSPENSION AND AXLES (6) If removed, heat ring gear with a heat lamp or PINION DEPTH MEASUREMENT AND by immersing in a hot fluid. The temperature should ADJUSTMENT WITH GAUGE SET 6575 not exceed 149°C (300°F). Do not use a torch to (1) Use pinion gear adjustment gauge set 6575 heat the ring gear.
Page 141 REAR SUSPENSION AND AXLES 3 - 39 Fig. 22 Depth Shim(s) Selection Fig. 21 Seating Pinion Bearings subtract that value from the thickness of the depth (8) Center the tool. Place a piece of 0.002 inch shim(s). If the number is 0, no change is necessary. shim stock at each end of the arbor tool.
Page 142 3 - 40 REAR SUSPENSION AND AXLES Fig. 25 Pinion Gear Seal Installation (19) Remove tools. Install Belleville washer. The convex side of the washer must face out- ward. Install the pinion nut. (20) Retain pinion yoke with Wrench C-3281. Ini- tially tighten the pinion gear shaft nut enough to re- Fig.
Page 143 REAR SUSPENSION AND AXLES 3 - 41 (2) Observe the reference marks and install the CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never ex- differential bearing caps at their original locations (Fig. 28). ceed specified preload torque.
Page 144 3 - 42 REAR SUSPENSION AND AXLES ring and pinion gear. Seat the bearing cups with the (5) Tighten the differential bearing cap bolts to 136 procedure described above. N m (100 ft. lbs.) torque. (6) Use Wrench C-4164 to tighten the right-side threaded adjuster to 95 N m (70 ft.
Page 145 REAR SUSPENSION AND AXLES 3 - 43 gear mate shaft. Do not remove the feeler clearance recorded when the C-clip lock was installed gauges, inspect the axle shaft with the feeler to thrust washer thickness measured. The sum will gauge inserted behind the side gear. If the end of determine the required thickness of the replacement the axle shaft is not contacting the pinion gear mate thrust washer.
Page 146 3 - 44 REAR SUSPENSION AND AXLES Fig. 33 Gear Teeth Contact Patterns...
Page 147 REAR SUSPENSION AND AXLES 3 - 45 TRAC-LOK DIFFERENTIAL OPERATION In a conventional differential, the torque applied to the ring gear is transmitted to the axle shafts through the differential gears. During normal operation, the torque transmitted to each wheel is equal at all times. However, if one wheel spins, the opposite wheel will generate only as much torque as the spinning wheel.
Page 148 3 - 46 REAR SUSPENSION AND AXLES (5) Use torque wrench on Special Tool 6790 to ro- DISASSEMBLY tate wheel and read rotating torque (Fig. 2). Service to the Trac-Lok differential requires the use of Tool Set C-4487 (J-23781). Refer to Model 35 Axle section in this Group for Differential Removal and Installation.
Page 149 REAR SUSPENSION AND AXLES 3 - 47 (2) Position the differential case on the axle shaft (Fig. 5). Place shop towels under the differential to avoid damage during removal of the ring gear (Fig. Fig. 7 Mate Shaft Lock Screw Fig.
Page 150 3 - 48 REAR SUSPENSION AND AXLES (8) Position a small screw driver in slot of Threaded Adapter C-4487-3 (Fig. 10 to prevent adapter from turning. Fig. 12 Pinion Gear Removal (12) Remove top side gear and clutch pack. Keep plates in correct order during removal (Fig.
Page 151 REAR SUSPENSION AND AXLES 3 - 49 (2) Inspect clutch pack plates for wear, scoring or damage. Replace both clutch packs if any one compo- nent in either pack is damaged. (3) Inspect side and pinion gears. Replace any gear that is worn, cracked, chipped or damaged.
Page 152 3 - 50 REAR SUSPENSION AND AXLES (14) Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (15) Install new ring gear bolts and alternately tighten to 95-122 N m (70-90 ft. lbs.) torque (Fig. 17). (17) Lubricate all differential components with hy- poid gear lubricant.
Page 153 REAR SUSPENSION AND AXLES 3 - 51 AXLE SPECIFICATIONS MODEL 35 AXLE 8 1/4 AXLE Axle Type .......Semi-Floating Hypoid Axle Type ........Semi-floating, hypoid Lubricant....SAE Thermally Stable 80W-90 Lubricant..........SAE 75W-90 Lubricant Trailer Tow.....Synthetic 75W-140 Lube Capacity ........2.08 L (4.4 pts.) Lube Capacity ......1.66 L (3.50 pts.) Axle Ratios .........3.07 3.55 4.10 Axle Ratio........3.07, 3.55, 3.73, 4.10 Differential...
Page 155 Brake Fluid/Lubricants/Cleaning Solvents ..2 Jeep Body Code Letters ..... 2 Brake Safety Precautions ....2...
Page 156 • Code letters YJ: Wrangler/YJ A different master cylinder, power brake booster, and HCU are used in the 1995 Jeep ABS system. The code letters are used throughout this group to The master cylinder reservoir has a single filler cap simplify model identification and component applica- and is no longer interconnected with the HCU.
Page 157 Once a faulty circuit has been identified, refer to hicle wheels and tires should all be the same size the appropriate chassis/body diagnostic manual for and type. However, the Jeep ABS system is designed individual component testing. to operate with a compact spare tire installed.
Page 158 5 - 4 SERVICE BRAKE DIAGNOSIS SERVICE BRAKE DIAGNOSIS INDEX page page Brake Drag ....... 6 Hard Pedal or High Pedal Effort .
Page 159 SERVICE BRAKE DIAGNOSIS 5 - 5 hand lever. Also note if vehicle was being operated especially on high mileage vehicles may cover struc- with parking brake partially applied (this will cause tural damage to such important components as red light to remain on). brakelines, rotors, support plates, and brake boost- (7) Check brake pedal operation.
Page 160 5 - 6 SERVICE BRAKE DIAGNOSIS pedal. The proper course of action is to bleed the sys- port or faulty power booster (binds-does not release). tem, or replace thin drums and suspect quality brake The condition will worsen as brake temperature in- lines and hoses.
Page 161 SERVICE BRAKE DIAGNOSIS 5 - 7 fied. This causes pull to switch direction in favor of ance. These are normal conditions and should not be mistaken for contamination. the brake unit that is functioning normally. If some type of oil has been added to the system, When diagnosing a change in pull condition, re- the fluid will separate into distinct layers.
Page 162 5 - 8 SERVICE BRAKE DIAGNOSIS produce a condition similar to grab as the tire loses Items to look for when diagnosing a parking brake and recovers traction. problem, are: • rear brakeshoe wear or adjuster problem Flat-spotted tires can cause vibration and wheel •...
Page 163 SERVICE BRAKE DIAGNOSIS 5 - 9 (7) Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vac- uum assisted pedal applications. If vacuum assist is not provided, perform booster and check valve vac- tests.
Page 164 Recommended Brake Fluid ....10 RECOMMENDED BRAKE FLUID Recommended brake fluid for Jeep vehicles is Mo- par brake fluid, or an equivalent fluid meeting SAE J1703 and DOT 3 standards.
Page 165 BRAKE FLUID—BRAKE BLEEDING—BRAKELINES AND HOSES 5 - 11 bubbles that are distributed throughout the hydrau- lic system. This will make extra bleeding operations necessary. • Bleed only one wheel brake unit at a time and use a bleed hose to bleed each wheel brake unit (Fig. 3). •...
Page 166 5 - 12 BRAKE FLUID—BRAKE BLEEDING—BRAKELINES AND HOSES connect scan tool and proceed to next step. (7) Repeat conventional bleed procedure described in steps (4) and (5). (8) Top off master cylinder fluid level and verify proper brake operation before moving vehicle. BRAKELINES AND HOSES Metal brakelines and rubber brake hoses should be inspected periodically and replaced if damaged.
Page 167 BRAKE FLUID—BRAKE BLEEDING—BRAKELINES AND HOSES 5 - 13 Fig. 6 Brakeline Routing (YJ With 4-Cylinder Engine) Fig. 7 Rear Brakeline Routing (XJ With ABS)
Page 168 5 - 14 BRAKE FLUID—BRAKE BLEEDING—BRAKELINES AND HOSES Fig. 8 Front Brakeline Routing (RHD XJ With ABS) Fig. 9 Front Brakeline Routing (RHD XJ Without Fig. 10 Master Cylinder/Combination Valve Connection (RHD XJ With ABS) ABS)
Page 169 MASTER CYLINDER—COMBINATION VALVE 5 - 15 MASTER CYLINDER—COMBINATION VALVE INDEX page page Combination Valve Replacement (Non-ABS) ..16 Master Cylinder Bench Bleeding ....21 General Service Information .
Page 170 5 - 16 MASTER CYLINDER—COMBINATION VALVE (2) Disconnect brake lines at master cylinder and combination valve. (3) Remove nuts attaching master cylinder to booster studs. (4) Remove master cylinder. (5) Remove cylinder cover and drain fluid. (6) If two-piece master cylinder reservoir requires service, refer to reservoir replacement procedure in this section.
Page 171 MASTER CYLINDER—COMBINATION VALVE 5 - 17 Fig. 5 Removing/Installing Primary Piston Fig. 7 Installing Secondary Piston (4) Push primary piston inward and install snap ring (Fig. 4). MASTER CYLINDER AND COMBINATION VALVE REMOVAL (WITH ABS) (1) Disconnect vent hoses at air cleaner cover. (2) Loosen clamp securing air cleaner hose to in- take manifold.
Page 172 5 - 18 MASTER CYLINDER—COMBINATION VALVE (5) Remove air cleaner housing from engine com- (9) Unseat small S-clip that secures brakelines partment. (Fig. 12). (6) Disconnect wire from combination valve pres- (10) Remove brakeline that connects master cylin- sure differential switch (Fig. 9). Do not pull wire to der front port to combination valve front port (Fig.
Page 173 MASTER CYLINDER—COMBINATION VALVE 5 - 19 Fig. 14 Location Of HCU Flexlines And HCU Line To Fig. 16 Master Cylinder Attaching Nut Removal Rear Brakes Fig. 17 Removing/Installing Reservoir Retaining Pins Fig. 15 Combination Valve And Brakeline Removal (17) Remove nuts attaching master cylinder to booster studs and remove cylinder (Fig.
Page 174 5 - 20 MASTER CYLINDER—COMBINATION VALVE (5) Remove reservoir by rocking it to one side and (9) Start reservoir in grommets. Then rock reser- pulling free of grommets (Fig. 19). voir back and forth while pressing downward to seat it in grommets. (10) Install pins that retain reservoir to cylinder body (Fig.
Page 175 MASTER CYLINDER—COMBINATION VALVE 5 - 21 brakeline to combination valve and master cylinder. Start brakelines by hand to avoid cross threading. (9) Tighten combination valve bracket attaching nut to 25 N m (220 in. lbs.) torque. (10) Install S-clip on lines from master cylinder to combination valve.
Page 176 5 - 22 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH INDEX page page Brake Pedal Installation ..... 31 Power Brake Booster Installation (XJ Without ABS) .
Page 177 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 23 Fig. 2 Brake Booster/Master Cylinder Assembly (YJ) POWER BRAKE BOOSTER OPERATION How Brake Boost Is Generated Power assist is generated by utilizing the pressure Booster Components differential between normal atmospheric pressure The booster assembly consists of a housing divided and a vacuum.
Page 178 5 - 24 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH Fig. 3 Power Brake Booster Internal Components POWER BRAKE BOOSTER REMOVAL (8) Disconnect brake booster vacuum hose at in- take manifold fitting (Fig. 7). Move hose aside for (XJ WITH ABS) working clearance. (1) Disconnect vacuum and vent hoses at air (9) Unseat small S-clip that secures brakelines cleaner cover.
Page 179 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 25 Fig. 6 Canister Vacuum Line Location (At Manifold Fitting) Fig. 7 Booster Vacuum Hose Removal/Installation (From Manifold Fitting) Fig. 4 Air Cleaner Components Fig. 8 Master Cylinder Front Brakeline Removal/ Installation Fig. 5 Pressure Differential Switch Wire Connection...
Page 180 5 - 26 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH Fig. 9 Disconnecting Master Cylinder Rear Brakeline (11) Disconnect master cylinder rear brakeline at cylinder. Then loosen line at combination valve and swing line around to opposite side of cylinder (Fig. 9). (12) Disconnect rear brakeline at HCU (Fig.
Page 181 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 27 Fig. 13 Disconnecting HCU Solenoid Harness Fig. 16 Push Rod Attachment At Brake Pedal Fig. 14 Disconnecting HCU Pump Harness Fig. 17 Brake Booster Positioned On Dash Panel POWER BRAKE BOOSTER INSTALLATION (XJ WITH ABS) (1) If new booster is being installed, install new check valve and vacuum hose (Fig.
Page 182 5 - 28 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH (8) Check condition of seal at rear of master cylin- (12) Install HCU as follows: (a) If only the HCU was removed, position HCU der (Fig. 22). Clean and reposition seal if dislodged. in mounting bracket.
Page 183 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 29 Fig. 23 HCU And Bracket Mounting (RHD Models) Fig. 25 Combination Valve Installation (22) Bleed brakes. Refer to procedure in Brake Fluid-Brake Bleeding-Brakelines And Hoses section. (23) Tighten brakeline fittings to 15-18 N m (130- 160 in.
Page 184 5 - 30 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH (11) Remove nuts attaching booster to passenger POWER BRAKE BOOSTER REMOVAL (YJ) compartment side of dash panel. (1) Disconnect brakelines at master cylinder. Then (12) In engine compartment, slide booster studs loosen lines at combination valve and move lines out of dash panel, tilt booster upward, and remove away from cylinder.
Page 185 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5 - 31 (3) Remove necessary dash panel-to-instrument panel brace rods. (4) Disconnect and remove brakelight switch. (5) Remove retainer clip securing booster push rod to pedal (Fig. 16). (6) Remove nut securing pedal shaft in support bracket.
Page 186 5 - 32 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH BRAKELIGHT SWITCH REMOVAL The brakelight switch is mounted in the pedal sup- port bracket and is operated by the pedal. The switch is secured in the bracket with a retainer (Fig. 30). (1) Remove steering column cover and lower trim panel for switch access, if necessary.
Page 187 Front Wheel Sensor Removal ....38 SYSTEM DESCRIPTION The Jeep antilock brake system (ABS) is an elec- tronically operated, all wheel brake control system. The system is designed to prevent wheel lockup and maintain steering control during periods of high wheel slip when braking.
Page 188 5 - 34 ABS OPERATION AND SERVICE MASTER CYLINDER/POWER BRAKE BOOSTER The ECU is located under the instrument panel in the passenger compartment. On YJ models, it is just A 25 mm bore master cylinder and 205 mm (8.07 above the heater plenum in line with the glove box. in.) dual diaphragm power brake booster are used for In left hand drive XJ models, it at the right side of all ABS applications (Fig.
Page 189 ABS OPERATION AND SERVICE 5 - 35 Fig. 4 Wheel Speed Sensors Fig. 5 Acceleration Switch ABS DIAGNOSTIC CONNECTOR A 12 volt power feed is supplied to the ECU and The ABS diagnostic connector is inside the vehicle. warning light when the ignition switch is in the Run The connector is the access point for the DRB scan position.
Page 190 5 - 36 ABS OPERATION AND SERVICE During normal braking, the master cylinder, power A pressure decrease cycle is initiated when speed booster and wheel brake units all function as they sensor signals indicate high wheel slip at one or would in a vehicle without ABS.
Page 191 ABS OPERATION AND SERVICE 5 - 37 rear axle shaft. The speed sensors generate a signal whenever a tone ring tooth rotates past the sensor pickup face. The wheel speed sensors provide the input signal to the ECU. If input signals indicate ABS mode brak- ing, the ECU causes the HCU solenoids to decrease, hold, or increase fluid apply pressure as needed.
Page 192 5 - 38 ABS OPERATION AND SERVICE air gap should be 0.40 to 1.3 mm (0.0157 to 0.051 (10) Verify sensor wire routing. Wire should loop forward and above sill bracket. Loose end of wire in.). If gap is incorrect, the sensor is either loose, or should be below sill bracket and towards brake hose.
Page 193 ABS OPERATION AND SERVICE 5 - 39 original sensor bolt. Use new bolt if original is worn (2) On YJ models, move driver seat forward or or damaged. rearward for access to sensor and mounting bracket (4) Install sensor bolt finger tight only at this time. (Fig.
Page 194 5 - 40 ABS OPERATION AND SERVICE CAUTION: The mercury switch (inside the accelera- tion switch), will not function properly if the switch is mispositioned. Verify that the switch locating ar- row is pointing to the front of the vehicle. (2) Position switch in mounting bracket.
Page 195 ABS OPERATION AND SERVICE 5 - 41 (2) Align and attach harness connector to ECU. HCU REMOVAL (XJ) Slide connector into engagement with tangs on ECU. A new design HCU is used in 1995 models. The Then tilt connector downward and into engagement new HCU has built-in accumulators that store the with ECU pin terminals.
Page 196 5 - 42 ABS OPERATION AND SERVICE (6) Disconnect both flex brakelines at HCU (Fig. 18). (9) If HCU mounting bracket will be left in place, it will be necessary to remove HCU solenoid harness connecter from mounting bracket. Remove connecter fasteners, by squeezing them closed with needle nose pliers;...
Page 197 ABS OPERATION AND SERVICE 5 - 43 HCU INSTALLATION (XJ) (1) Install HCU as follows: (a) If only the HCU was removed, position HCU in mounting bracket. Then install and tighten three shoulder bolts that attach HCU to bracket (Figs. 23 and 24). One bolt is used at forward end of bracket and two at rear as shown.
Page 198 5 - 44 ABS OPERATION AND SERVICE HCU REMOVAL (YJ) (1) Place shop towels under master cylinder and HCU brakelines. (2) Disconnect flex lines at upper part of HCU. (3) Disconnect solenoid and pump harness wires at HCU harness connecters. (4) Disconnect lines to front/rear brakes at lower part of HCU.
Page 199 Wheel Nut Tightening ..... . 54 GENERAL INFORMATION Jeep XJ/YJ models are equipped with single piston, floating-type disc brake calipers. Ventilated, cast ro- tors are used for all applications.
Page 200 5 - 46 DISC BRAKES The amount of piston retraction is determined by brakelining wear. Generally, the amount is just enough to maintain contact between the piston and inboard brakeshoe. Brakelining running clearance at the rotor, will be held between zero and a maximum of 0.12 mm (0.005 in.).
Page 201 DISC BRAKES 5 - 47 (8) Remove outboard shoe. Press one end of shoe inward to disengage shoe lug. Then rotate shoe up- ward until retainer spring clears caliper. Press oppo- site end of shoe inward to disengage shoe lug and rotate shoe up and out of caliper (Fig.
Page 202 5 - 48 DISC BRAKES Fig. 11 Installing Inboard Brakeshoe Fig. 13 Caliper Installation Fig. 12 Installing Outboard Brakeshoe install caliper over rotor and seat upper ends of brakeshoes on top mounting ledge (Fig. 11). CAUTION: Before securing the caliper, be sure the caliper brake hose is not twisted, kinked or touch- Fig.
Page 203 DISC BRAKES 5 - 49 (2) Pad interior of caliper with minimum, 2.54 cm (4) Remove caliper piston dust boot (Fig. 17). Col- lapse boot with suitable tool and remove and discard (1 in.) thickness of shop towels or rags (Fig. 15). Tow- boot.
Page 204 5 - 50 DISC BRAKES CALIPER CLEANING AND INSPECTION Clean the caliper and piston with Mopar brake cleaner, clean brake fluid, or denatured alcohol only. Do not use gasoline, kerosene, thinner, or similar sol- vents. These products leave a residue that will dam- age pistons and seals.
Page 205 DISC BRAKES 5 - 51 Fig. 25 Front Brake Hose And Fitting Components Fig. 23 Installing Caliper Piston CAUTION: If new caliper bolts are being installed, or if the original reason for repair was a drag/pull condition, check caliper bolt length before proceed- ing.
Page 206 5 - 52 DISC BRAKES Fig. 26 Rotor And Hub Fig. 27 Securing 4 x 4 Rotor For Lateral Runout Check (4) Install new spring nuts on wheel studs. (5) Install wheel and lower vehicle. DISC BRAKE ROTOR THICKNESS Rotor minimum usable thickness is 22.7 mm (0.89 in.).
Page 207 DISC BRAKES 5 - 53 DISC BRAKE ROTOR REFINISHING When To Refinish Rotor braking surfaces can be refinished by sand- ing and/or machining in a disc brake lathe. However, the rotor should be cleaned and inspected before- hand. Careful inspection will avoid refinishing rotors with very little service life left in them.
Page 208 5 - 54 DISC BRAKES The correct tightening sequence is important in avoiding rotor and drum distortion. The correct se- quence is in a diagonal crossing pattern (Fig. 32). Recommended torque range for XJ/YJ wheel nuts is 108-149 N m (80-110 ft. lbs.). Preferred set-to torque is 129 N m (95 ft.
Page 209 DRUM BRAKES 5 - 55 DRUM BRAKES INDEX page page Brake Drum Refinishing ....58 Wheel Cylinder Installation ....58 Drum Brake Adjustment .
Page 210 5 - 56 DRUM BRAKES Fig. 2 Ten Inch Drum Brake Components Fig. 3 Shoe Contact Surfaces (9-Inch Support Plate) (6) Attach parking brake lever to secondary brake- shoe. Use new washer and U-clip to secure lever. (7) Remove wheel cylinder clamps. (8) Attach parking brake cable to lever.
Page 211 DRUM BRAKES 5 - 57 (6) Turn adjuster star wheel (by hand) to expand or retract brakeshoes. Continue adjustment until gauge outside legs are light drag-fit on shoes (Fig. 7). (7) Repeat adjustment at opposite brakeshoe as- Fig. 5 Adjuster Screw Components (9-Inch Brake) DRUM BRAKE ADJUSTMENT Rear drum brakes are equipped with a self adjust- ing mechanism.
Page 212 5 - 58 DRUM BRAKES (5) Tighten brakeline fitting to 15 N m (132 in. lbs.) torque. (6) Install brakeshoes. Adjust shoes to drum with brake gauge. (7) Install brake drums and lower vehicle. (8) Fill master cylinder and bleed brakes. SUPPORT PLATE REPLACEMENT The support plate should cleaned and inspected whenever the drum brake components are being ser-...
Page 213 DRUM BRAKES 5 - 59 If the brake drums are heavily coated with rust, tightening the nuts or tightening them in the wrong sequence can cause distortion of the brake rotors and clean and inspect them carefully. Rust damage on drums.
Page 214 5 - 60 PARKING BRAKES PARKING BRAKES INDEX page page General Service Information ....60 Parking Brake Lever Removal (XJ with Full Console) . 63 Parking Brake Cable Tensioner Adjustment (XJ/YJ) .
Page 215 PARKING BRAKES 5 - 61 secondary brakeshoes move the shoes directly into Struts installed between each brakeshoe, are used to contact with the drum braking surface. The actuating maintain shoe alignment and equal motion when the levers are interconnected by a system of cables and a parking brakes are applied.
Page 216 5 - 62 PARKING BRAKES Fig. 4 Tensioner E-Clip And Retaining Pin Location Fig. 3 Parking Brake Switch Mounting (6) Disconnect parking brake switch wire at switch PARKING BRAKE LEVER REMOVAL (XJ WITH MINI (Fig. 3). CONSOLE) (7) Remove parking brake lever assembly from (1) Release parking brakes, if necessary.
Page 217 PARKING BRAKES 5 - 63 (12) Parking brake switch can be serviced at this (11) Verify correct parking brake operation. time, if necessary. PARKING BRAKE LEVER REMOVAL (XJ WITH FULL PARKING BRAKE LEVER INSTALLATION (XJ WITH CONSOLE) MINI CONSOLE) (1) Release parking brakes. (1) Assemble lever and tensioner components (Figs.
Page 218 5 - 64 PARKING BRAKES (8) Remove shift handle by pulling upward sharply on handle. Then remove shift bezel (Fig. 7). (9) Remove console cover screws (Figs. 9 and 10). (10) On models with power mirror switch, pry switch out of console cover and disconnect switch connector (Fig.
Page 219 PARKING BRAKES 5 - 65 Fig. 11 Full Console Components (XJ) (3) Remove adjusting nut from tensioner rod. Then PARKING BRAKE LEVER INSTALLATION (XJ temporarily secure equalizer and cables to nearby WITHOUT CONSOLE) chassis component with wire. (1) Assemble lever and tensioner (Figs. 4 and 5). (4) Lower vehicle.
Page 220 5 - 66 PARKING BRAKES PARKING BRAKE PEDAL REMOVAL (YJ) (1) Raise vehicle. (2) Loosen equalizer nuts until front cable is slack (Fig. 13). Fig. 13 Front Cable And Equalizer (YJ) (3) Lower vehicle. (4) Remove dash-to-instrument panel brace rod, if equipped.
Page 221 PARKING BRAKES 5 - 67 (9) Install brake drum and wheel. (10) Engage cable in equalizer and install equal- izer nuts (Fig. 15). (11) Adjust parking brakes. Refer to procedure in this section. Fig. 14 Parking Brake Pedal Assembly (YJ) PARKING BRAKE REAR CABLE REPLACEMENT (XJ) (1) Raise vehicle and loosen equalizer nuts until rear cables are slack.
Page 222 5 - 68 PARKING BRAKES Fig. 17 Parking Brake Components (YJ) PARKING BRAKE REAR CABLE REPLACEMENT (YJ) PARKING BRAKE SWITCH (1) Raise vehicle and loosen equalizer nuts (Fig. The parking brake switch is located on the lever 17). assembly on XJ models, or on the foot pedal assem- (2) Remove clamp and cotter pin attaching rear ca- bly on YJ models (Fig.
Page 223 PARKING BRAKES 5 - 69 PARKING BRAKE CABLE TENSIONER ADJUSTMENT (7) Raise vehicle again. (8) Mark tensioner rod 6.5 mm (1/4 in.) from ten- (XJ/YJ) sioner bracket (Fig. 19). Parking brake adjustment is only necessary (9) Tighten adjusting nut at equalizer until mark when the tensioner, or a cable has been re- on tensioner rod moves into alignment with tensioner placed or disconnected for service.
Page 224 5 - 70 PARKING BRAKES SPECIFICATIONS BRAKE TORQUE SPECIFICATIONS...
Page 225 CLUTCH 6 - 1 CLUTCH CONTENTS page page CLUTCH DIAGNOSIS ..... . 3 GENERAL INFORMATION ....1 CLUTCH SERVICE .
Page 226 6 - 2 CLUTCH CLUTCH OPERATION mitted to the slave cylinder through a connecting line. In turn, the slave cylinder operates the clutch Leverage, clamping force, and friction are what release lever. make the clutch work. The disc serves as the friction The clutch release bearing is mounted on the element and a diaphragm spring and pressure plate provide the clamping force.
Page 227 CLUTCH DIAGNOSIS 6 - 3 CLUTCH DIAGNOSIS INDEX page page Clutch Contamination ..... . . 3 Flywheel Runout ......3 Clutch Cover and Disc Runout .
Page 228 6 - 4 CLUTCH DIAGNOSIS when handling the cover and disc. Impact can distort Improper clutch cover bolt tightening can distort the cover, diaphragm spring, release fingers and the the cover. The usual result is clutch grab, chatter hub of the clutch disc. and rapid wear.
Page 229 CLUTCH DIAGNOSIS 6 - 5 Fig. 1 Clutch Inspection Points...
Page 230 6 - 6 CLUTCH DIAGNOSIS...
Page 231 CLUTCH DIAGNOSIS 6 - 7...
Page 232 6 - 8 CLUTCH DIAGNOSIS...
Page 233 CLUTCH DIAGNOSIS 6 - 9...
Page 234 6 - 10 CLUTCH SERVICE CLUTCH SERVICE INDEX page page Clutch Component Lubrication ....10 Clutch Pedal Installation ....15 Clutch Cover and Disc Installation .
Page 235 CLUTCH SERVICE 6 - 11 Fig. 2 Clutch Disc And Pressure Plate Inspection Fig. 3 Typical Method Of Aligning Clutch Disc (4) Position clutch disc on flywheel. Be sure side of (10) Tighten cover bolts evenly and in rotation a disc marked flywheel side is positioned against fly- few threads at a time.
Page 236 6 - 12 CLUTCH SERVICE Fig. 5 Manual Transmission Mounting (2.5L) (2) Disconnect release bearing from release lever and remove bearing (Fig. 6). (3) Inspect bearing slide surface of transmission front bearing retainer. Replace retainer if slide sur- face is scored, worn, or cracked. (4) Inspect release fork and fork pivot.
Page 237 CLUTCH SERVICE 6 - 13 Fig. 7 Pilot Bearing Installation Fig. 8 Clutch Housing Attachment (8) Install transmission. Refer to Group 21 for pro- right and left hand drive models are basically cedure. the same. Only master cylinder location is dif- ferent.
Page 238 6 - 14 CLUTCH SERVICE CLUTCH HYDRAULIC LINKAGE INSTALLATION (1) Be sure reservoir cover on clutch master cylin- der is tight to avoid spills. (2) Position clutch linkage components in vehicle. Work connecting line and slave cylinder downward past engine and adjacent to clutch housing. (3) Position clutch master cylinder on dash panel (Fig.
Page 239 CLUTCH SERVICE 6 - 15 Fig. 13 Clutch Master Cylinder Reservoir And Cap Fig. 14 Reservoir Fluid Level Indicator Ring If inspection or diagnosis indicates additional fluid (2) Disconnect clutch pedal position switch wires. may be needed, use Mopar brake fluid, or an equiv- (3) Remove retainer clip that attaches clutch mas- alent meeting standards SAE J1703 and DOT 3.
Page 240 6 - 16 CLUTCH SERVICE (3) Install clutch master cylinder push rod on is replaced and use Mopar Lock N’ Seal, or Loctite pedal. Secure rod with washer(s) and new cotter pin. 242 on the replacement bolt threads. (4) Connect clutch pedal position switch wires. Recommended flywheel bolt torques are: •...
Page 241 CLUTCH SERVICE 6 - 17 CAUTION: Do not use water, or compressed air to TORQUE SPECIFICATIONS cool the flywheel. The rapid cooling produced by water or compressed air can distort, or crack the gear and flywheel.
Page 243 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page DIAGNOSIS ......4 GENERAL INFORMATION .
Page 244 7 - 2 COOLING SYSTEM Fig. 1 Coolant Flow—XJ Models with 2.5L 4-Cylinder Engine—Typical Fig. 2 Coolant Flow—YJ Models with 2.5L 4-Cylinder Engine—Typical...
Page 245 COOLING SYSTEM 7 - 3 Fig. 3 Coolant Flow—XJ Models with 4.0L 6- Fig. 4 Coolant Flow—YJ Models with 4.0L 6- Cylinder Engine—Typical Cylinder Engine—Typical...
Page 246 7 - 4 COOLING SYSTEM DIAGNOSIS DIAGNOSIS INDEX page page DRB Scan Tool ......5 Preliminary Checks .
Page 247 COOLING SYSTEM DIAGNOSIS 7 - 5 ERASING TROUBLE CODES After the problem has been repaired, the DRB scan tool must be used to erase a DTC. Refer to the ap- propriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool. DRB SCAN TOOL For operation of the DRB scan tool, refer to the ap- propriate Powertrain Diagnostic Procedures service...
Page 248 7 - 6 COOLING SYSTEM DIAGNOSIS COOLING SYSTEM DIAGNOSIS...
Page 249 COOLING SYSTEM DIAGNOSIS 7 - 7 COOLING SYSTEM DIAGNOSIS (CONT.)
Page 250 7 - 8 COOLING SYSTEM DIAGNOSIS COOLING SYSTEM DIAGNOSIS (CONT.)
Page 251 COOLING SYSTEM DIAGNOSIS 7 - 9 COOLING SYSTEM DIAGNOSIS (CONT.)
Page 252 7 - 10 COOLING SYSTEM DIAGNOSIS COOLING SYSTEM DIAGNOSIS (CONT.)
Page 253 COOLING SYSTEM DIAGNOSIS 7 - 11 COOLING SYSTEM DIAGNOSIS (CONT.)
Page 254 7 - 12 COOLING SYSTEM DIAGNOSIS COOLING SYSTEM DIAGNOSIS (CONT.)
Page 255 COOLING SYSTEM SERVICE PROCEDURES 7 - 13 SERVICE PROCEDURES INDEX page page Auxiliary Electric Cooling Fan—XJ Models with 4.0L Refilling Cooling System ....21 6-Cylinder Engine .
Page 256 7 - 14 COOLING SYSTEM SERVICE PROCEDURES The water pump on all models can be removed without discharging the air conditioning system (if equipped). CAUTION: All engines have a reverse (counter- clockwise) rotating water pump. The letter R is stamped into the back of the water pump impeller (Fig.
Page 257 COOLING SYSTEM SERVICE PROCEDURES 7 - 15 The engine accessory drive belt must be removed Fig. 6 P.S. Pump Front Mounting Bolt/Locknut— Typical Fig. 4 Fan Mounting Nuts prior to removing the fan (if installed at pump) or fan pulley. (4) Remove engine drive belt as follows: (a) Loosen two rear power steering pump mount- ing bolts A (Fig.
Page 258 7 - 16 COOLING SYSTEM SERVICE PROCEDURES (11) Remove idler pulley mounting bolt and remove idler pulley. This must be done to gain clearance for the water pump mounted heater hose fitting when water pump is being removed. Note position of pulley spacers after removal.
Page 259 COOLING SYSTEM SERVICE PROCEDURES 7 - 17 INSTALLATION—ALL MODELS (1) If pump is being replaced, install the heater hose fitting to the pump. Use a sealant on the fitting such as Mopar™ Thread Sealant With Teflon. Refer to the directions on the package. (2) Clean the gasket mating surfaces.
Page 260 7 - 18 COOLING SYSTEM SERVICE PROCEDURES ON-BOARD DIAGNOSTICS XJ and YJ models are equipped with On-Board Di- agnostics for certain cooling system components. Re- fer to On-Board Diagnostics (OBD) in the Diagnosis section of this group for additional information. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trou- ble Code (DTC) in the PCM memory.
Page 261 COOLING SYSTEM SERVICE PROCEDURES 7 - 19 Fig. 15 Hose Clamp Tool—Typical Fig. 17 Thermostat Removal/Installation Fig. 16 Clamp Number/Letter Location INSTALLATION (1) Install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the engine.
Page 262 7 - 20 COOLING SYSTEM SERVICE PROCEDURES COOLANT CAUTION: Do not use coolant additives that are claimed to improve engine cooling. GENERAL INFORMATION The cooling system is designed around the coolant. COOLANT SERVICE Coolant flows through the engine water jackets ab- It is recommended that the cooling system be sorbing heat produced during engine operation.
Page 263 COOLING SYSTEM SERVICE PROCEDURES 7 - 21 Low coolant level can cause thermostat pellet to be suspended in air instead of coolant. This will cause thermostat to open later, which in turn causes higher coolant temperature. Air trapped in cooling system also reduces amount of coolant circulating in heater core resulting in low heat output.
Page 264 ULTRAVIOLET LIGHT METHOD tings. Attach a section of radiator hose to the radia- All Jeep models have a leak detection additive tor bottom outlet fitting and insert the flushing gun. added to the cooling system before they leave the fac- Connect a water supply hose and air supply hose to tory.
Page 265 COOLING SYSTEM SERVICE PROCEDURES 7 - 23 Operate the tester pump to apply 124 kPa (18 psi) pressure to the system. If the hoses enlarge exces- sively or bulge while testing, replace as necessary. Observe the gauge pointer and determine the condi- tion of the cooling system according to the following criteria: •...
Page 266 7 - 24 COOLING SYSTEM SERVICE PROCEDURES ant will then be drawn from the coolant tank and re- CAUTION: Do not operate the engine with a spark plug shorted for more than a minute. The catalytic turned to a proper level in the radiator. The coolant reserve/overflow system consists of a converter may be damaged.
Page 267 COOLING SYSTEM SERVICE PROCEDURES 7 - 25 Fig. 24 Reserve/Overflow Tank—XJ Models—With Right Hand Drive TANK REMOVAL/INSTALLATION (1) Remove the tube clamp at the tank and remove tube. (2) On YJ models, remove the windshield washer reservoir and its mounting bracket. Fig.
Page 268 7 - 26 COOLING SYSTEM SERVICE PROCEDURES (4) When checking for vacuum leaks. cooling system problems. A pressure cap that does not have a history of coolant loss should not be re- WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, placed just because it leaks slowly when tested WAIT AT LEAST 15 MINUTES BEFORE REMOVING with this tool.
Page 269 COOLING SYSTEM SERVICE PROCEDURES 7 - 27 WARNING: CONSTANT TENSION HOSE CLAMPS XJ MODELS WITH 2.5L 4-CYLINDER ENGINE ARE USED ON MOST COOLING SYSTEM HOSES. REMOVAL WHEN REMOVING OR INSTALLING, USE ONLY (1) Disconnect negative battery cable at battery. TOOLS DESIGNED FOR SERVICING THIS TYPE OF (2) Observe the previous WARNINGS.
Page 270 7 - 28 COOLING SYSTEM SERVICE PROCEDURES Fig. 29 Radiator Remove/Install—XJ Models—2.5L 4-Cylinder Engine DRAINCOCK WITH THE SYSTEM HOT AND PRES- SURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.
Page 271 COOLING SYSTEM SERVICE PROCEDURES 7 - 29 (4) For access to radiator draincock, remove radia- tor grille mounting screws and remove grill. Refer to Group 23, Body for procedures. (5) Attach one end of a 24 inch long X 1/4 inch ID hose to the radiator draincock.
Page 272 7 - 30 COOLING SYSTEM SERVICE PROCEDURES (13) Remove four radiator upper crossmember bolts (Fig. 32) and remove upper crossmember. (14) If equipped with air conditioning, separate ra- diator from condenser by removing condenser-to-radi- ator mounting brackets (Fig. 33). Fig. 34 Radiator Installation—XJ Models with 4.0L 6-Cylinder Engine bracket at bottom of radiator.
Page 273 COOLING SYSTEM SERVICE PROCEDURES 7 - 31 (8) Remove six radiator mounting bolts. Position WAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. the front axle vent hose (Fig. 35) to the side. (9) Lift radiator straight up and out of vehicle tak- ing care not to damage radiator fins.
Page 274 7 - 32 COOLING SYSTEM SERVICE PROCEDURES (10) Check and adjust automatic transmission fluid level (if equipped). COOLING SYSTEM HOSES Rubber hoses route coolant to and from the radia- tor, intake manifold and heater core. All XJ models equipped with air conditioning have a coolant control valve.
Page 275 COOLING SYSTEM SERVICE PROCEDURES 7 - 33 After removing fan blade/viscous fan drive assem- bly, do not place thermal viscous fan drive in hori- zontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assem- bly and contaminate lubricant.
Page 276 7 - 34 COOLING SYSTEM SERVICE PROCEDURES VISCOUS FAN DRIVE CAUTION: If the viscous fan drive is replaced be- cause of mechanical damage, the cooling fan DESCRIPTION AND OPERATION blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could Also refer to the previous section on Cooling Sys- have resulted from excessive vibration.
Page 277 COOLING SYSTEM SERVICE PROCEDURES 7 - 35 (5) Be sure that the air conditioner (if equipped) is turned off. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DI- RECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 278 7 - 36 COOLING SYSTEM SERVICE PROCEDURES nostic Procedures manual for diagnostic information radiator mounted transmission oil cooler, engine cool- and operation of the DRB scan tool. ant may become mixed with transmission fluid or To test operation of the fan relay only, refer to Re- transmission fluid may enter engine cooling system.
Page 279 COOLING SYSTEM SERVICE PROCEDURES 7 - 37 REMOVAL/INSTALLATION—XJ MODELS (1) Remove the grill mounting screws and remove the grill. Refer to Group 23, Body for procedures. (2) Place a drain pan below the transmission oil cooler. (3) Remove the two hose clamps at oil cooler inlet and outlet tubes (Figs.
Page 280 7 - 38 ENGINE ACCESSORY DRIVE BELTS ENGINE ACCESSORY DRIVE BELTS INDEX page page Automatic Belt Tensioner—XJ Models with Right Belt Tension Specifications ....38 Hand Drive .
Page 281 ENGINE ACCESSORY DRIVE BELTS 7 - 39 SERPENTINE DRIVE BELT DIAGNOSIS...
Page 282 7 - 40 ENGINE ACCESSORY DRIVE BELTS SERPENTINE DRIVE BELT DIAGNOSIS (CONT.) Fig. 2 YJ Models with 4.0L Engine, and XJ Models Fig. 3 YJ Models With 2.5L or 4.0L Engine, and XJ with 2.5L Engine—With A/C Models with 2.5L Engine—Without A/C BELT SERVICE—EXCEPT RIGHT HAND DRIVE REPLACEMENT/ADJUSTMENT Belt tension is adjusted at the power steering...
Page 283 ENGINE ACCESSORY DRIVE BELTS 7 - 41 Fig. 4 XJ Models with 4.0L Engine—Without A/C—Except RHD Fig. 6 XJ Models With 4.0L Engine—With A/C—With Fig. 5 XJ Models With 4.0L Engine—With A/C— Except RHD (1) Loosen two rear power steering pump mounting bolts A (Fig.
Page 284 7 - 42 ENGINE ACCESSORY DRIVE BELTS REMOVAL (1) Attach a socket/wrench to the mounting bolt of the automatic tensioner pulley (Fig. 7). (2) Rotate the tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. (3) Remove belt from idler pulley (Fig.
Page 285 ENGINE ACCESSORY DRIVE BELTS 7 - 43 INSTALLATION (1) Install pulley and pulley bolt to tensioner. Tighten bolt to 90 N m (65 ft. lbs.) torque. (2) Install tensioner assembly to mounting bracket. An alignment pin is located on the back of tensioner. Align this pin to the slotted hole in the mounting bracket.
Page 286 7 - 44 ENGINE BLOCK HEATER ENGINE BLOCK HEATER GENERAL INFORMATION (2) Unplug power cord from block heater. (3) Loosen screw in center of block heater (Figs. 11, 12 or 13). DESCRIPTION AND OPERATION (4) Remove block heater from cylinder block. An optional engine block heater is available for all models.
Page 287 COOLING SYSTEM SPECIFICATIONS 7 - 45 SPECIFICATIONS GENERAL INFORMATION BELT TENSION—EXCEPT RIGHT HAND DRIVE (RHD) MODELS The following specifications are published from the latest information available at the time of publica- tion. If anything differs between the specifica- tions found on the Vehicle Emission Control Information (VECI) label and the following specifications, use specifications on VECI label.
Page 288 7 - 46 COOLING SYSTEM SPECIFICATIONS TORQUE...
Page 289 ELECTRICAL 8A - 1 ELECTRICAL GROUP INDEX Group Group AUDIO SYSTEMS ......8F POWER SEATS ......8R BATTERY/STARTER/GENERATOR SERVICE .
Page 290 8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 1 Starting System Components (Typical) Fig. 2 Charging System Components (Typical) BATTERY GENERAL INFORMATION movement of electrons produces a flow of electrical current through the load device attached to the bat- The storage battery is a device used to store elec- tery terminals.
Page 291 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3 charged. However, even with these vents, hydrogen (2) Cranking Capacity This can be determined gas can collect in or around the battery. If hydrogen by performing a battery load test, which measures gas is exposed to flame or sparks, it can ignite. the ability of the battery to supply high-amperage If the electrolyte level is low, the battery could arc current.
Page 292 8A - 4 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS BATTERY DIAGNOSIS...
Page 293 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 5 WARNING: DO NOT USE OPEN FLAME AS A SOURCE OF ADDITIONAL LIGHT FOR VIEWING TEST INDICATOR. EXPLOSIVE HYDROGEN GAS MAY BE PRESENT IN THE AREA SURROUNDING BATTERY. Fig. 2 Built-In Test Indicator Sight Glass HYDROMETER TEST The hydrometer test reveals the battery state-of- charge by measuring the specific gravity of the elec-...
Page 294 8A - 6 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS the specific gravity for temperature variation. Test OPEN CIRCUIT VOLTAGE the specific gravity of the electrolyte in each battery cell. Example: A battery is tested at -12.2°C (10°F) and has a specific gravity of 1.240. Determine the actual specific gravity as follows: (1) Determine the number of degrees above or be- low 26.7°C (80°F):...
Page 295 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 7 Fig. 4 Volt-Amps-Load Tester (Typical) Fig. 7 Load 50% CCA Rating - Note Voltage test, the battery will be somewhat warmer. See Load Test Temperature chart for proper loaded voltage reading. (7) If the voltmeter reading falls below 9.6 volts, at a minimum battery temperature of 21°C (70°F), re- place the battery.
Page 296 8A - 8 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS (1) Battery Capacity—A completely discharged WARNING: POISONOUS AND CAUSTIC. BATTERY CONTAINS SULFURIC ACID. AVOID CONTACT WITH heavy-duty battery requires twice the recharging time of a small capacity battery. SKIN, EYES, OR CLOTHING. IN EVENT OF CON- TACT, FLUSH WITH WATER AND CALL PHYSICIAN WARNING: NEVER...
Page 297 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 9 with polarity sensing circuitry. This circuitry protects CHARGE RATE the charger and/or battery from being damaged if im- properly connected. If the battery state-of-charge is too low for the polarity sensing circuitry to detect, the charger will not operate.
Page 298 8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS IGNITION-OFF DRAW GENERAL INFORMATION The test lamp may light brightly for up to 3 min- utes, or may not light at all, depending upon the ve- Ignition-Off Draw (IOD) refers to power being hicle’s electrical equipment. The term brightly, as drained from the battery with the ignition switch used throughout the following tests, implies the turned OFF.
Page 299 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11 STARTING SYSTEM GENERAL INFORMATION lever in the starter. This engages the starter overrun- ning clutch and pinion gear with the flywheel/drive The starting system (Fig. 1) consists of: • ignition switch plate ring gear. •...
Page 300 8A - 12 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS STARTING SYSTEM DIAGNOSIS...
Page 301 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 13 • place transmission in NEUTRAL (manual trans- COLD CRANKING TEST mission) or PARK (automatic transmission) (1) Battery must be fully-charged and load tested • parking brake is applied before proceeding. See Battery, in this group. •...
Page 302 8A - 14 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS • wiring harness and connections. (4) Connect voltmeter to measure between the bat- tery negative post and a good clean ground on the Test procedures for these components are as fol- engine block (Fig. 5). Rotate and hold ignition switch lows, and should be followed in the order described.
Page 303 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 15 Remove starter relay from PDC to perform the fol- lowing tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to next step.
Page 304 8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 2.5L STARTER NOISE DIAGNOSIS See Starter Noise Diagnosis chart. If the complaint is similar to Conditions 1 and 2 in chart, correction can be achieved by shimming starter according to the following procedures: Disconnect the battery negative cable to pre- vent inadvertent starting of engine.
Page 305 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 17 CHARGING SYSTEM GENERAL INFORMATION The charging system consists of: • generator • voltage regulator circuitry (within PCM) • ignition switch • battery • generator warning lamp or voltmeter (depending on vehicle equipment) • wiring harness and connections. Following is a general description of the major charging system components.
Page 306 8A - 18 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS • accessories being left on with the engine not run- CAUTION: Do not connect green/orange A142 field ning wire to ground. Refer to Group 8W - Wiring Dia- • a faulty or improperly adjusted switch that allows grams for more information.
Page 307 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 19 CHARGING SYSTEM DIAGNOSIS (5) Connect positive lead of a test voltmeter (range TEST 0-18 volts minimum) to generator battery output ter- (1) Start engine. Immediately after starting, re- minal. duce engine speed to idle. (6) Connect negative lead of test voltmeter to a (2) Adjust carbon pile and engine speed in incre- good ground.
Page 308 8A - 20 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Fig. 2 Generator Output Wire Resistance Test (Typical) (2) After current output test is completed, reduce (5) Remove jumper wire (Fig. 3). engine speed, turn OFF carbon pile and turn OFF ig- (6) Connect generator output wire to generator nition switch.
Page 309 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 21 Fig. 3 Generator Current Output Test (Typical)
Page 310 8A - 22 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS USING ON-BOARD DIAGNOSTIC SYSTEM GENERAL INFORMATION to be set. Therefore, it is important that the test pro- cedures be followed in sequence, to understand what The Powertrain Control Module (PCM) monitors caused a DTC to be set. critical input and output circuits of the charging sys- See Generator Diagnostic Trouble Code chart for tem, making sure they are operational.
Page 311 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 23 SPECIFICATIONS BATTERY SPECIFICATIONS 2.5L STARTER AND SOLENOID TESTING SPECIFICATIONS BATTERY CLASSIFICATIONS AND RATINGS STARTING SYSTEM SPECIFICATIONS 2.5L STARTING SYSTEM COLD CRANKING 4.0L STARTER AND SOLENOID TESTING SPECIFICATIONS SPECIFICATIONS CHARGING SYSTEM SPECIFICATIONS 4.0L STARTING SYSTEM COLD CRANKING OUTPUT VOLTAGE SPECIFICATIONS SPECIFICATIONS GENERATOR RATINGS...
Page 313 BATTERY/STARTER/GENERATOR SERVICE 8B - 1 BATTERY/STARTER/GENERATOR SERVICE CONTENTS page page BATTERY ....... 1 SPECIFICATIONS .
Page 314 8B - 2 BATTERY/STARTER/GENERATOR SERVICE and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3). Replace cables that have damaged or deformed terminals. Fig. 5 Battery Holddown—YJ (5) Inspect battery tray (Fig. 6 or 7) and hold- downs for corrosion or damage.
Page 315 BATTERY/STARTER/GENERATOR SERVICE 8B - 3 Fig. 9 Clean Battery (9) Clean corrosion from battery posts (Fig. 10) Fig. 7 Battery Tray—YJ with a wire brush or post and terminal cleaner, and pry cell caps off (Fig. 8). Do not use a screwdriver. sodium bicarbonate (baking soda) and warm water Add distilled water to each cell until the liquid cleaning solution.
Page 316 8B - 4 BATTERY/STARTER/GENERATOR SERVICE terminal clamp. Both cable clamp bolts require CAUTION: Be certain that battery cables are con- nected to the correct battery terminals. Reverse po- torque of 8.5 N m (75 in. lbs.). larity can damage electrical components. (14) Apply a thin coating of petroleum jelly or chassis grease to cable terminals and battery posts.
Page 317 BATTERY/STARTER/GENERATOR SERVICE 8B - 5 (4) Remove nut from lower end of brace rod (auto- matic transmission only). (5) Remove brace rod and bracket (automatic transmission only). (6) Remove nut, bolt and bracket from bell housing (manual transmission only). (7) Disconnect battery cable and solenoid feed wire from solenoid (Fig.
Page 318 8B - 6 BATTERY/STARTER/GENERATOR SERVICE Fig. 16 Power Distribution Center—YJ Fig. 15 Power Distribution Center—XJ (3) Install starter relay by aligning relay terminals STARTER RELAY REMOVE/INSTALL with cavities in PDC and plugging relay in. (1) Disconnect battery negative cable. (4) Connect negative cable to battery. (2) Remove starter relay by unplugging unit from (5) Test relay operation.
Page 319 BATTERY/STARTER/GENERATOR SERVICE 8B - 7 the belt is installed incorrectly, causing the engine to overheat. Refer to the belt routing label in engine compartment, or refer to Belt Schematics in Group 7 - Cooling System. GENERATOR REMOVE/INSTALL—RIGHT-HAND DRIVE WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE FROM GENERATOR.
Page 320 8B - 8 BATTERY/STARTER/GENERATOR SERVICE SPECIFICATIONS BATTERY SPECIFICATIONS TORQUE—4.0L TORQUE STARTER SPECIFICATIONS TORQUE—2.5L GENERATOR SPECIFICATIONS TORQUE...
Page 321 XJ When the ignition switch is turned ON again, the (Cherokee) models. Following are general descrip- thermometer will display the memory temperature tions of major components used in the overhead con- for one minute;...
Page 322 8C - 2 OVERHEAD CONSOLE DIAGNOSIS COMPASS/DISPLAY SELF-DIAGNOSTIC TEST This self-diagnostic test is used to determine that the compass and all of its display segments are oper- ating properly electrically. Initiate the self-diagnostic test as follows: (1) With the ignition switch in the OFF position, simultaneously press and hold the COMP/TEMP but- ton and the US/METRIC button.
Page 323 OVERHEAD CONSOLE 8C - 3 (5) Remove jumper wire from temperature sensor harness connector. Check continuity between cavities 10 and 11 of overhead console harness connector and a good ground (Fig. 2). There should be no continuity. If OK, replace electronic module. If not OK, repair short circuit as required.
Page 324 8C - 4 OVERHEAD CONSOLE COMPASS/THERMOMETER DIAGNOSIS...
Page 325 OVERHEAD CONSOLE 8C - 5 SERVICE PROCEDURES COMPASS VARIATION ADJUSTMENT ity of the compass. DO NOT use magnetic tools when servicing the overhead console. Variance is the difference between magnetic north and geographic north. In some areas, the difference The compass features a self-calibrating design, between magnetic and geographic north is great which simplifies the calibration procedure.
Page 326 8C - 6 OVERHEAD CONSOLE (4) With the degaussing tool still energized, slowly OVERHEAD CONSOLE REMOVE/INSTALL back it away from the screw until the tool is at least (1) Remove screw forward of the compass unit (Fig. 2 feet from the screw head, then unplug the tool. (5) Place an 8-1/2 X 11 inch piece of paper, oriented lengthwise from front to rear, on the center line of the roof at the windshield header (Fig.
Page 327 OVERHEAD CONSOLE 8C - 7 (3) Unhook torque spring from wall and put in down position as shown by arrow in Fig. 10. Fig. 7 Disconnect Wire Harnesses Fig. 10 Release Torque Spring (4) Remove sunglasses storage bin door by flexing the center panel.
Page 328 8C - 8 OVERHEAD CONSOLE (8) Snap cover plate back in position as shown in Fig. 9. Some pressure from the inside of the bin may be required to engage all 6 snaps. READING/COURTESY LAMP BULB REMOVE/ INSTALL (1) Make a hook in the end of a large paper clip or wire (approximately 0.06 in.
Page 329 IGNITION SYSTEMS 8D - 1 IGNITION SYSTEMS CONTENTS page page COMPONENT IDENTIFICATION/SYSTEM IGNITION SWITCH—XJ MODELS ... 26 OPERATION ......1 IGNITION SWITCH—YJ MODELS .
Page 330 8D - 2 IGNITION SYSTEMS Fig. 1 PDC—XJ Models Fig. 4 Distributor Assembly—Typical The camshaft position sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft (Fig.
Page 331 IGNITION SYSTEMS 8D - 3 CRANKSHAFT POSITION SENSOR The crankshaft position sensor is mounted to the transmission bellhousing at the left/rear side of the engine block (Figs. 5, 6 or 7). Fig. 5 Crankshaft Position Sensor—2.5L 4-Cyl. Engine—Typical Fig. 7 Crankshaft Position Sensor—4.0L 6-Cyl. Engine—YJ models With Automatic Transmission SENSOR OPERATION The flywheel/drive plate has groups of four notches...
Page 332 8D - 4 IGNITION SYSTEMS groups of four pulses generated on 2.5L 4-cylinder engines. There are 3 groups of four pulses generated on 4.0L 6-cylinder engines. The trailing edge of the fourth notch, which causes the pulse, is four degrees before top dead center (TDC) of the corresponding piston.
Page 333 IGNITION SYSTEMS 8D - 5 On the 4.0L 6-cylinder engine, the ignition coil is mounted to a bracket on the side of the engine (to the front of the distributor) (Fig. 11). Fig. 12 PCM Location—XJ Models Fig. 11 Ignition Coil—Typical For component testing, refer to the Diagnostics/Ser- vice Procedures section of this group.
Page 334 8D - 6 IGNITION SYSTEMS DIAGNOSTICS/SERVICE PROCEDURES INDEX page page Automatic Shutdown (ASD) Relay Test ..6 Ignition Timing ......11 Camshaft Position Sensor Test .
Page 335 IGNITION SYSTEMS 8D - 7 (8) If voltage is not present at supply wire, check for voltage at pin-7 of powertrain control module (PCM) 60-way connector. Leave the PCM connector connected for this test. (9) If voltage is still not present, perform vehicle test using the DRB scan tool.
Page 336 8D - 8 IGNITION SYSTEMS Fig. 6 Cap Inspection—External—Typical Fig. 4 Crankshaft Position Sensor—4.0L 6-Cyl. Engine—YJ models With Auto. Trans. Fig. 7 Cap Inspection—Internal—Typical Fig. 5 Crankshaft Position Sensor Connector cap. Fully seat the cables onto the towers. If neces- sary, refer to the engine Firing Order diagrams (Figs.
Page 337 IGNITION SYSTEMS 8D - 9 the appropriate Powertrain Diagnostics Procedures manual. To test the coil only, refer to the following: The ignition coil (Fig. 11) is designed to operate without an external ballast resistor. Fig. 9 Firing Order—4.0L 6-Cylinder Engine Fig.
Page 338 8D - 10 IGNITION SYSTEMS IGNITION SECONDARY CIRCUIT DIAGNOSIS or burn marks. Repair as necessary. If steady arcing occurs, connect ignition coil cable to the distributor CHECKING FOR SPARK cap. (3) Remove a cable from one spark plug. CAUTION: When disconnecting a high voltage cable (4) Using insulated pliers, hold the cable terminal from a spark plug or from the distributor cap, twist approximately 12 mm (1/2 in.) from the engine cylin-...
Page 339 IGNITION SYSTEMS 8D - 11 (4) Crank the engine for 5 seconds while monitor- IGNITION TIMING ing the voltage at the coil positive terminal: Base (initial) ignition timing is NOT adjust- • If the voltage remains near zero during the entire able on any of the 2.5L 4-cylinder or 4.0L 6-cyl- period of cranking, refer to On-Board Diagnostics in inder engines.
Page 340 8D - 12 IGNITION SYSTEMS Fig. 18 PCM Location—XJ Models Fig. 19 Normal Operation and Cold (Carbon) Fouling For diagnostics, refer to the appropriate Powertrain Some fuel refiners in several areas of the United Diagnostic Procedures service manual for operation States have introduced a manganese additive (MMT) of the DRB scan tool.
Page 341 IGNITION SYSTEMS 8D - 13 plugs with scavenger deposits can be considered nor- mal in condition and can be cleaned using standard procedures. Fig. 22 Scavenger Deposits CHIPPED ELECTRODE INSULATOR Fig. 20 Oil or Ash Encrusted A chipped electrode insulator usually results from bending the center electrode while adjusting the subjected to a high torque load, deposits partially liq- spark plug electrode gap.
Page 342 8D - 14 IGNITION SYSTEMS temperature ranges. This depends upon the thick- Check the high-tension cable connections for good ness and length of the center electrodes porcelain in- contact at the ignition coil, distributor cap towers sulator.) and spark plugs. Terminals should be fully seated. The terminals and spark plug covers should be in good condition.
Page 343 IGNITION SYSTEMS 8D - 15 To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap.
Page 344 8D - 16 IGNITION SYSTEMS DTC, refer to On-Board Diagnostics. This can be found in the General Diagnosis sections of Group 14, Fuel System. For numeric flash lamp code charts, refer to Diagnostic Trouble Code (DTC). This can also be found in the General Diagnosis sections of Group 14, Fuel System.
Page 345 IGNITION SYSTEMS 8D - 17 COMPONENT REMOVAL/INSTALLATION INDEX page page Automatic Shutdown (ASD) Relay ... . . 17 Intake Manifold Air Temperature Sensor ..23 Camshaft Position Sensor .
Page 346 8D - 18 IGNITION SYSTEMS Fig. 3 Camshaft Position Sensor Fig. 5 Crankshaft Position Sensor—4.0L 6-Cylinder Engine—All Except YJ models With Automatic transmission bellhousing at the left/rear side of the Transmission engine block (Figs. 4, 5 or 6). On all 2.5L 4-cylinder and 4.0L 6-cylinder engines (except YJ models with an automatic transmission and 4.0L 6-cylinder engine) the sensor is attached with two bolts.
Page 347 IGNITION SYSTEMS 8D - 19 CAUTION: On some models, two bolts are used to secure the sensor to the transmission. These bolts are specially machined to correctly space the unit to the flywheel. Do not attempt to install any other bolts.
Page 348 8D - 20 IGNITION SYSTEMS terclockwise direction while lifting up the distributor. REMOVAL—2.5L OR 4.0L ENGINE (1) Disconnect the negative battery cable at the This is due to the helical cut gears on the distributor battery. and camshaft. Note the removed position of the rotor during dis- (2) Disconnect coil secondary cable at coil.
Page 349 IGNITION SYSTEMS 8D - 21 (2) Check the position of the slot on the oil pump (11) 2.5L 4-Cylinder Engine: Pre-position the dis- gear. On the 2.5L engine, it should be just slightly tributor into the engine while holding the centerline before (counterclockwise of) the 10 o’clock position of the base slot in the 1 o’clock position (Fig.
Page 350 8D - 22 IGNITION SYSTEMS (12) Install the distributor holddown clamp and bolt. Tighten the bolt to 23 N m (17 ft. lbs.) torque. (13) Remove the pin punch tool from the distribu- tor. Or, if the plastic alignment pin was used, remove it straight down from the bottom of the distributor.
Page 351 IGNITION SYSTEMS 8D - 23 (3) Remove ignition coil mounting bolts (nuts are INSTALLATION used on back side of bracket). Remove coil. (1) Check the pins in the PCM 60-way electrical connector for damage. Repair as necessary. INSTALLATION (2) Install PCM. Tighten mounting bolts to 1 N m (1) Install ignition coil to bracket on cylinder block (9 in.
Page 352 8D - 24 IGNITION SYSTEMS motion. Never pull directly on the cable. Internal damage to cable will result. Fig. 19 Cable Removal (2) Prior to removing the spark plug, spray com- pressed air around the spark plug hole and the area Fig.
Page 353 IGNITION SYSTEMS 8D - 25 Fig. 22 Engine Firing Order—4.0L 6-Cylinder Engine Fig. 21 Engine Firing Order—2.5L 4-Cylinder Engine THROTTLE POSITION SENSOR (TPS) When installing new cables, make sure a positive connection is made. A snap should be felt when a For an operational description, diagnosis and re- good connection is made between the plug cable and moval/installation procedures, refer to Group 14,...
Page 354 8D - 26 IGNITION SYSTEMS IGNITION SWITCH—XJ MODELS IGNITION SWITCH AND KEY CYLINDER SERVICE The ignition switch is located on the steering col- umn. The Key-In-Switch and Halo Light are integral with the ignition switch. Refer to Group 8U for Key- In-Switch and Halo Light diagnosis for XJ models.
Page 355 IGNITION SYSTEMS 8D - 27 Fig. 4 Key-In-Switch and Halo Lamp Connector Fig. 6 Key Cylinder Retaining Screw Fig. 5 Key Cylinder Retaining Screw INSTALLATION (1) Connect electrical connectors to ignition switch. Make sure that switch locking tabs are fully seated in wiring connectors.
Page 356 8D - 28 IGNITION SYSTEMS Fig. 8 Key Cylinder Removal Fig. 10 Ignition Switch Mounting Pad (b) Insert ignition key into lock cylinder. While gently pushing lock cylinder in toward ignition switch, rotate ignition key to end of travel. (6) Install retaining screw into bracket and lock cylinder.
Page 357 IGNITION SYSTEMS 8D - 29 IGNITION SWITCH—YJ MODELS GENERAL INFORMATION This section will cover the electrical portion of the ignition switch. To service the mechani- cal ignition key switch, refer to Group 19, Steering. Refer to Group 8W, Wiring for ignition switch wir- ing circuits.
Page 358 8D - 30 IGNITION SYSTEMS spring loaded to release when the key is released. The maximum voltage drop between any two con- nected terminals should not exceed 12.5 millivolts per amp. For example: If a 10 amp load is drawn through the switch, maximum voltage drop should be 10 x 0.0125 or 0.125 volt.
Page 359 IGNITION SYSTEMS 8D - 31 (10) Install the windshield wiper intermittent con- trol module and its bracket (if equipped). (11) Install the negative battery cable. Test dimmer switch. Test ignition switch operation in all switch positions. If equipped with a tilt steer- ing column, test operation of dimmer switch and ig- nition switch in all tilt positions.
Page 360 8D - 32 IGNITION SYSTEMS SPECIFICATIONS GENERAL INFORMATION ENGINE FIRING ORDER—4.0L 6-CYLINDER ENGINE The following specifications are published from the latest information available at the time of publica- tion. If anything differs between the specifica- tions found on the Vehicle Emission Control Information (VECI) label and the following specifications, use specifications on VECI label.
Page 361 Two basic instrument cluster options are offered on Modular instrument panel construction allows all XJ (Cherokee) models. One is referred to as a low- gauges and controls to be serviced from the front of line cluster, and the other is referred to as a high- the panel.
Page 362 8E - 2 INSTRUMENT PANEL AND GAUGES—XJ The high-line cluster includes the following gauges: temperature. High sending unit resistance causes • coolant temperature gauge low coolant temperature readings. Low resistance • fuel gauge causes high coolant temperature readings. • oil pressure gauge The gauge will read at the high end of the scale •...
Page 363 INSTRUMENT PANEL AND GAUGES—XJ 8E - 3 voltage is supplied to one side of the indicator bulb. A TACHOMETER The tachometer gives an indication of engine speed ground path for the bulb is provided by 3 switches. in Revolutions-Per-Minute (RPM). With the engine The bulb will light when: •...
Page 364 8E - 4 INSTRUMENT PANEL AND GAUGES—XJ emission system related circuits or components, the HEADLAMP HIGH BEAM INDICATOR LAMP The high beam indicator lamp is controlled by the lamp is turned on. This will indicate that the PCM headlamp dimmer (multi-function) switch. One side has recorded a Diagnostic Trouble Code (DTC) in of the indicator bulb is grounded at all times.
Page 365 INSTRUMENT PANEL AND GAUGES—XJ 8E - 5 DIAGNOSIS GAUGES If an individual gauge is inoperative, see the diag- nostic procedure under the heading for that gauge. If more than one gauge is inoperative, perform the fol- lowing: (1) Check fuse 17 (fuse 26 - RHD) in the fuseblock module.
Page 366 8E - 6 INSTRUMENT PANEL AND GAUGES—XJ Fig. 3 Oil Pressure Switch/Sending Unit - Typical Fig. 2 Fuel Gauge Sending Unit Connector (5) Still probing cavity B7 (cavity B8 - RHD) of (5) Probe cavity B1 of cluster connector A. Check cluster connector A, check for continuity to sending for continuity to a good ground.
Page 367 INSTRUMENT PANEL AND GAUGES—XJ 8E - 7 (3) Probe cavity A6 of cluster connector A. Check for continuity to a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (4) Still probing cavity A6 of cluster connector A, check for continuity to cavity 43 of PCM connector.
Page 368 8E - 8 INSTRUMENT PANEL AND GAUGES—XJ LOW-LINE GAUGE CLUSTER...
Page 369 INSTRUMENT PANEL AND GAUGES—XJ 8E - 9 HIGH-LINE GAUGE CLUSTER (LHD)
Page 370 8E - 10 INSTRUMENT PANEL AND GAUGES—XJ TELL-TALE CLUSTER (LHD)
Page 371 INSTRUMENT PANEL AND GAUGES—XJ 8E - 11 CLUSTER CONNECTORS (RHD)
Page 372 8E - 12 INSTRUMENT PANEL AND GAUGES—XJ INDICATOR LAMPS (4) Check continuity between cavity 6 of cluster connector B and cavity 52 of ABS control module con- If an individual indicator lamp is inoperative, see nector (Fig. 6). There should be continuity. If OK, re- the diagnostic procedure under the heading for that fer to Group 5 - Brakes for diagnosis of ABS control lamp.
Page 373 INSTRUMENT PANEL AND GAUGES—XJ 8E - 13 Connect battery negative cable and turn ignition (2) Turn ignition switch to ON. Disconnect coolant switch to ON. Lamp should light. If OK, repair open temperature switch connector (Fig. 1). Jump switch circuit to brake warning switch. If not OK, replace connector to ground.
Page 374 8E - 14 INSTRUMENT PANEL AND GAUGES—XJ (2) Disconnect battery negative cable. Remove in- connector. There should be continuity. If not OK, re- strument cluster bezel and cluster assembly. Unplug pair open circuit as required. cluster connector A. Connect battery negative cable. LOW WASHER FLUID WARNING LAMP Turn headlamps on and select high beam.
Page 375 INSTRUMENT PANEL AND GAUGES—XJ 8E - 15 ignition switch to ON. Lamp should light. If OK, go to next step. If not OK, replace bulb. (3) Turn ignition switch to OFF. Disconnect battery negative cable. Unplug cluster connector B. Check for continuity between cavity 2 (cavity 15 - RHD) of clus- ter connector B and a good ground.
Page 376 8E - 16 INSTRUMENT PANEL AND GAUGES—XJ CLUSTER ILLUMINATION LAMPS Turn park lamps on at headlamp switch. Rotate headlamp switch knob counterclockwise to just before (1) Check fuse 19 (fuse 25 - RHD) in fuseblock interior lamps detent. Check for battery voltage at module.
Page 377 INSTRUMENT PANEL AND GAUGES—XJ 8E - 17 SERVICE PROCEDURES CLUSTER ASSEMBLY REMOVE/INSTALL (1) Disconnect battery negative cable. (2) Remove upper and lower steering column shrouds and steering column to instrument panel be- zel gap hider. If equipped with tilt steering, apply tape to tilt mechanism on top of steering column to protect instrument panel bezel from damage during removal.
Page 378 8E - 18 INSTRUMENT PANEL AND GAUGES—XJ Fig. 10 Instrument Cluster (2) If equipped with trip odometer, gently pull and mask (Fig. 10). knob off trip odometer push pin. Remove cluster lens...
Page 379 INSTRUMENT PANEL AND GAUGES—XJ 8E - 19 Fig. 11 Printed Circuit Remove/Install (3) Remove gauge attaching screws from rear of cluster housing (Fig. 11). Remove gauge from front of housing. (4) Reverse removal procedures to install. PRINTED CIRCUIT REMOVE/INSTALL GAUGE CLUSTER (1) Remove cluster assembly as described in Clus- ter Assembly Remove/Install.
Page 380 8E - 20 INSTRUMENT PANEL AND GAUGES—XJ Fig. 15 Headlamp Switch Remove/Install (5) Disconnect the wire harness connector from the switch. (6) Remove the headlamp switch from the instru- ment panel. (7) Reverse removal procedures to install. INSTRUMENT PANEL REMOVE/INSTALL (1) Disconnect battery negative cable.
Page 381 INSTRUMENT PANEL AND GAUGES—XJ 8E - 21 Fig. 16 Instrument Panel Exploded View Fig. 17 Driver’s Side Defroster Cowl Retaining Clip...
Page 382 8E - 22 INSTRUMENT PANEL AND GAUGES—XJ Fig. 18 Instrument Panel Install...
Page 383 INSTRUMENT PANEL AND GAUGES—XJ 8E - 23 SPECIFICATIONS GAUGE CLUSTER...
Page 384 8E - 24 INSTRUMENT PANEL AND GAUGES—YJ INSTRUMENT PANEL AND GAUGES—YJ CONTENTS page page INSTRUMENT PANEL AND GAUGES—YJ ..22 SERVICE PROCEDURES ....31 DIAGNOSIS .
Page 385 INSTRUMENT PANEL AND GAUGES—YJ 8E - 25 The gauge needle moves as the movable permanent TACHOMETER magnet aligns itself to the changing magnetic fields The tachometer gives an indication of engine speed created around it by the electromagnets. in Revolutions-Per-Minute (RPM). With the engine running, the tachometer receives an engine speed COOLANT TEMPERATURE GAUGE pulse signal from the Powertrain Control Module...
Page 386 8E - 26 INSTRUMENT PANEL AND GAUGES—YJ voltage is supplied to one side of the indicator bulb. A sition. A timer in the chime/buzzer module controls ground path for the bulb is provided by 3 switches. ignition-switched battery feed to the lamp. Refer to The bulb will light when: Group 8U - Chime/Buzzer Warning Systems for more •...
Page 387 INSTRUMENT PANEL AND GAUGES—YJ 8E - 27 DIAGNOSIS GAUGES If an individual gauge is inoperative, see the diag- nostic procedure under the heading for that gauge. If more than one gauge in the main cluster or gauge package cluster is inoperative, perform the following: (1) Check fuse 9 in the fuseblock module.
Page 388 8E - 28 INSTRUMENT PANEL AND GAUGES—YJ Fig. 2 Fuel Gauge Sending Unit Connector Fig. 3 Oil Pressure Sending Unit - Typical continuity. If OK, go to next step. If not OK, repair (3) Turn ignition switch to OFF. Disconnect battery circuit to ground as required.
Page 389 INSTRUMENT PANEL AND GAUGES—YJ 8E - 29 Fig. 4 Vehicle Speed Sensor Connector TACHOMETER (1) With engine running, check for tachometer sig- nal at pin 43 of PCM connector (Fig. 5). See Tachom- eter Calibration chart in Specifications. If OK, go to next step.
Page 390 8E - 30 INSTRUMENT PANEL AND GAUGES—YJ MAIN CLUSTER...
Page 391 INSTRUMENT PANEL AND GAUGES—YJ 8E - 31 GAUGE PACKAGE CLUSTER...
Page 392 8E - 32 INSTRUMENT PANEL AND GAUGES—YJ INDICATOR LAMPS If an individual indicator lamp is inoperative, see the diagnostic procedure under the heading for that lamp. If more than one indicator lamp or a combina- tion of lamps and gauges in the main cluster or the gauge package cluster is inoperative, see Gauges in this section for diagnosis.
Page 393 INSTRUMENT PANEL AND GAUGES—YJ 8E - 33 (9) Turn ignition switch to START position and (3) Turn ignition switch to OFF. Disconnect battery hold there. Check for continuity between terminal for negative cable. Unplug cluster connector. Check for circuit G11 of ignition switch and a good ground. continuity between cavity 2 of cluster connector and There should be continuity.
Page 394 8E - 34 INSTRUMENT PANEL AND GAUGES—YJ (4) Check for continuity between cavity 5 of cluster TURN SIGNAL INDICATOR LAMPS (1) Disconnect battery negative cable. Remove left connector and cavity 54 of PCM connector. There instrument cluster bezel and main cluster assembly. should be continuity.
Page 395 INSTRUMENT PANEL AND GAUGES—YJ 8E - 35 SERVICE PROCEDURES CLUSTER ASSEMBLY REMOVE/INSTALL MAIN CLUSTER (1) Disconnect battery negative cable. (2) Remove 6 screws from left instrument cluster bezel (Fig. 8). Fig. 9 Main Cluster Remove/Install Fig. 8 Left Cluster Bezel Remove/Install (3) Slide bezel toward steering wheel.
Page 396 8E - 36 INSTRUMENT PANEL AND GAUGES—YJ Fig. 10 Main Cluster...
Page 397 INSTRUMENT PANEL AND GAUGES—YJ 8E - 37 GAUGE PACKAGE CLUSTER (1) Disconnect battery negative cable. (2) Remove 6 screws from center instrument clus- ter bezel (Fig. 11). (3) Remove 6 cluster assembly mounting screws (Fig. 12). (4) Unplug the connector from cluster. (5) Reverse removal procedures to install.
Page 398 8E - 38 INSTRUMENT PANEL AND GAUGES—YJ Fig. 12 Gauge Package Cluster...
Page 399 INSTRUMENT PANEL AND GAUGES—YJ 8E - 39 GAUGES REMOVE/INSTALL (4) Remove 3 screws that retain gauge from rear of cluster housing (Fig. 15) and remove gauge. MAIN CLUSTER (1) Remove cluster as described in Cluster Remove/ Install. (2) Remove 3 screws from speedometer or tachom- eter lens (Fig.
Page 400 8E - 40 INSTRUMENT PANEL AND GAUGES—YJ Fig. 17 Printed Circuit Remove/Install (5) Remove screws that retain gauge from rear of cluster housing and remove gauge. (6) Reverse removal procedures to install. PRINTED CIRCUIT REMOVE/INSTALL MAIN CLUSTER (1) Remove main cluster as described in Cluster Remove/Install.
Page 401 INSTRUMENT PANEL AND GAUGES—YJ 8E - 41 (5) To remove plate, slide it toward bottom of hous- ing (Fig. 19). Fig. 21 Cluster Connector Retaining Plate (6) Remove all lamp holders from the printed cir- cuit. Fig. 19 Cluster Connector Retaining Plate (7) Remove printed circuit including connector.
Page 402 8E - 42 INSTRUMENT PANEL AND GAUGES—YJ HEADLAMP OR PANEL DIMMER SWITCH REMOVE/INSTALL (1) Disconnect battery negative cable. (2) Remove 6 screws from left instrument cluster bezel (Fig. 22). Fig. 23 Indicator Panel Holding Tabs Fig. 22 Left Cluster Bezel Remove/Install (3) Slide bezel toward steering wheel.
Page 403 INSTRUMENT PANEL AND GAUGES—YJ 8E - 43 SPECIFICATIONS MAIN CLUSTER GAUGE PACKAGE CLUSTER...
Page 405 Following are general descriptions of major compo- The IOD fuse should be checked if the radio station nents used in XJ (Cherokee)/YJ (Wrangler) audio sys- preset memory or clock functions are erratic or inop- tems. Refer to Group 8W - Wiring Diagrams for erative.
Page 406 8F - 2 AUDIO SYSTEMS ANTENNA External suppression devices that are serviceable and should be checked in the case of RFI or EMI All models use a fixed-length stainless steel rod- noise complaints include the following: type antenna mast, installed at the right front (fend- •...
Page 407 AUDIO SYSTEMS 8F - 3 RADIO DIAGNOSIS...
Page 408 8F - 4 AUDIO SYSTEMS (2) Resistance value between terminals 85 and 86 RADIO CONNECTIONS (electromagnet) is 75 5 ohms. (3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. RADIO ILLUMINATION RELAY CONNECTIONS RELAY CIRCUIT TESTS RADIO ILLUMINATION RELAY...
Page 409 AUDIO SYSTEMS 8F - 5 (5) The coil ground terminal (85) is connected to TEST 2 the electromagnet in the relay. Check as follows: Test 2 checks the antenna for an open circuit as fol- (a) On YJ models, it is grounded at all times. lows: There should be continuity to ground at cavity for (1) Disconnect the antenna cable lead from the ra-...
Page 410 8F - 6 AUDIO SYSTEMS SERVICE PROCEDURES RADIO REMOVE/INSTALL - XJ (5) Slide radio chassis out of instrument panel far enough to disconnect radio electrical connector, (1) Disconnect battery negative cable. ground lead and antenna lead (Fig. 6). Remove radio (2) Remove upper and lower steering column from instrument panel.
Page 411 AUDIO SYSTEMS 8F - 7 Fig. 11 Control Panel Remove/Install - XJ Fig. 8 Parking Brake Remove/Install - XJ (3) Remove latch release and control panel assem- bly. (4) Remove armrest lower retaining screws. (5) Swing armrest downward to a vertical position. This is necessary to disconnect armrest from upper retainer clip (Fig.
Page 412 8F - 8 AUDIO SYSTEMS Fig. 13 Trim Panel Remove - XJ (2) Carefully remove grille from speaker by placing fingertips on outer circumference of grille and gently prying straight down to disengage 4 mounting tabs. (3) Drill out rivets securing speaker to sound bar. (4) Lower speaker far enough to unplug wiring Fig.
Page 413 AUDIO SYSTEMS 8F - 9 SPEAKERS REMOVE/INSTALL - YJ INSTRUMENT PANEL - YJ RIGHT SIDE The speaker is located behind grille panel at right end of the instrument panel. (1) Reach up behind instrument panel and remove 4 stamped nuts holding the speaker in place. (2) Disconnect speaker electrical connector and re- move speaker.
Page 414 8F - 10 AUDIO SYSTEMS Fig. 20 Sound Bar Attaching Bolt - YJ Fig. 19 Sound Bar Speaker Connector - YJ (3) Remove screws holding speaker grille and speaker to bar. (4) Disconnect wires from speaker and remove speaker. (5) Reverse removal procedures to install. SOUND BAR REMOVE/INSTALL - YJ (1) Disconnect speaker harness connector located on the passenger side at the sound bar (Fig.
Page 415 Following are general descriptions of the major steering column. On YJ models, the horn relay is a components in the XJ (Cherokee)/YJ (Wrangler) horn ISO relay installed in the Power Distribution Center systems. Refer to Group 8W - Wiring Diagrams for (PDC) near the battery tray.
Page 416 8G - 2 HORNS DIAGNOSIS WARNING: ON VEHICLES EQUIPPED WITH AN AIR- BAG, REFER TO GROUP 8M - RESTRAINT SYS- TEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POS- SIBLE PERSONAL INJURY.
Page 417 HORNS 8G - 3 SERVICE PROCEDURES HORN REMOVE/INSTALL (1) Raise and support the vehicle. (2) Remove the front underbody splash shield. (3) Remove horn mounting bolt and horn (Fig. 3). Fig. 4 Horn Mounting - YJ (1) Disconnect negative cable from battery and iso- late.
Page 418 8G - 4 HORNS Fig. 5 Airbag Module Remove/Install (3) Remove horn button components (Fig. 6). (4) Reverse removal procedures to install. (5) Connect negative cable to battery. HORN CONTACT/CLOCKSPRING Refer to Group 19 - Steering for information on ser- vice of the horn switch contact (YJ) or clockspring (XJ).
Page 419 HORNS 8G - 5 SPECIFICATIONS...
Page 421 The vehicle speed control system (Fig. 1) is an the speed control vacuum servo diaphragm and the available option on all XJ (Cherokee) models. The throttle control linkage. This cable causes the throt- system is electronically controlled and vacuum oper- tle control linkage to open or close the throttle valve ated.
Page 422 8H - 2 VEHICLE SPEED CONTROL SYSTEM Fig. 1 Vehicle Speed Control System WARNING: THE USE OF VEHICLE SPEED CON- CONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC TROL IS NOT RECOMMENDED WHEN DRIVING OR ON ROADS THAT ARE WINDING, ICY, SNOW CONDITIONS DO NOT PERMIT MAINTAINING A COVERED, OR SLIPPERY.
Page 423 VEHICLE SPEED CONTROL SYSTEM 8H - 3 DIAGNOSIS CHART 1...
Page 424 8H - 4 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS CHART 2...
Page 425 VEHICLE SPEED CONTROL SYSTEM 8H - 5 USING ON-BOARD DIAGNOSTIC SYSTEM Refer to the Powertrain Diagnostic Procedures man- ual to diagnose an on-board diagnostic system trou- The Powertrain Control Module (PCM) monitors ble code. critical input and output circuits of the speed control system, making sure they are operational.
Page 426 8H - 6 VEHICLE SPEED CONTROL SYSTEM SPEED CONTROL SWITCH WARNING: ON VEHICLES EQUIPPED WITH AN AIR- BAG, REFER TO GROUP 8M - RESTRAINT SYS- TEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POS- SIBLE PERSONAL INJURY.
Page 427 VEHICLE SPEED CONTROL SYSTEM 8H - 7 for pin 2 (Fig. 6). If OK, go to next step. If not OK, see diagnosis for Stop Lamp Switch. Fig. 6 Servo Harness Connector Fig. 4 Speed Control Servo - LHD Fig. 7 Powertrain Control Module (2) Connect negative lead of voltmeter to a good body ground near the module.
Page 428 8H - 8 VEHICLE SPEED CONTROL SYSTEM RESUME or SET position, the voltmeter should read battery voltage. If not, perform the Speed Control Switch Test. If the switch is not at fault, then check the main harness and repair as necessary. (7) Touch the positive lead of the voltmeter to the terminal in cavity number 49.
Page 429 VEHICLE SPEED CONTROL SYSTEM 8H - 9 SERVICE PROCEDURES SPEED CONTROL SERVO REMOVE/INSTALL SPEED CONTROL SWITCH REMOVE/INSTALL (1) Disconnect battery negative cable. WARNING: ON VEHICLES EQUIPPED WITH AN AIR- (2) Disconnect vacuum hose at servo. BAG, REFER TO GROUP 8M - RESTRAINT SYS- (3) Remove 2 nuts on servo cable sleeve.
Page 430 8H - 10 VEHICLE SPEED CONTROL SYSTEM SERVO CABLE REMOVE/INSTALL (3) Squeeze tabs on speed control cable and push out of locking plate (Fig. 12). Unclip cable from cable (1) Remove air cleaner. guide. (2) Using finger pressure only, remove speed con- trol cable connector at bellcrank by pushing connec- tor off the bellcrank (Fig.
Page 431 GENERAL INFORMATION Following are general descriptions of the major TURN SIGNAL FLASHER (YJ ONLY) components in the XJ (Cherokee)/YJ (Wrangler) The turn signal flasher is located in the fuseblock model turn signal and hazard warning systems. Refer module. It contains one fixed contact point and one to Group 8W - Wiring Diagrams for complete circuit contact point attached to a flexible bimetal arm.
Page 432 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS • turn signals allowing current flow to the lamps. As the bimetal • hazard warning strip cools, the contact points are pushed open and • headlamp beam selection the cycle repeats. •...
Page 433 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DIAGNOSIS When diagnosing the turn signal or hazard warning place faulty combination flasher. If not OK, remove circuits, remember that high generator output can test flasher and go to next step. burn out bulbs rapidly and repeatedly.
Page 434 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS lamps and repair circuits or replace bulbs as re- (2) Replace hazard warning flasher (metal can in quired. If system still does not function properly, pro- fuseblock module) with a known good unit. Test op- ceed as follows.
Page 435 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 SERVICE PROCEDURES WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, (4) Remove both upper and lower shrouds from col- REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE umn (Fig. 5). ATTEMPTING STEERING WHEEL COMPONENT DIAGNO- (5) Remove lower fixed column shroud.
Page 436 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS Fig. 8 Lockplate Remove Fig. 7 Steering Wheel Remove/Install (6) Remove vibration damper from the steering col- umn hub, if equipped. (7) Remove the steering wheel using a steering wheel puller. DO NOT hammer on puller or end of steering shaft.
Page 437 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 (15) Remove turn/hazard switch attaching screws. (20) Remove 2 nuts holding steering column (16) Remove 6 housing screws (Fig. 10). bracket to brake sled (Fig. 12). (21) Remove 4 bolts holding steering column bracket to column.
Page 438 8J - 8 TURN SIGNAL AND HAZARD WARNING SYSTEMS (24) Pry up locking tabs of steering column connec- tor and remove connector from column bracket. (25) Tape connector to wires as shown (Fig. 14). Fig. 15 Remove Plastic Harness Cover (28) To install a new switch, reverse the removal procedure.
Page 439 Following are general descriptions of the major both the liftgate wiper and washer. Refer to the own- components in the XJ (Cherokee) wiper and washer er’s manual for more information on liftgate wiper/ systems. Refer to Group 8W - Wiring Diagrams for washer system controls and operation.
Page 440 8K - 2 WIPER AND WASHER SYSTEMS - XJ The two pivot cranks are joined by a connecting link, INTERMITTENT WIPE MODULE and a drive link connects the motor crank to the drive In addition to low and high speed, the optional inter- link near the left pivot.
Page 441 WIPER AND WASHER SYSTEMS - XJ 8K - 3 DIAGNOSIS - XJ WINDSHIELD WIPER SYSTEM and test wiper operation in all modes. If OK, replace faulty intermittent wipe module. If not OK, re-install (1) Remove in-line circuit breaker near fuseblock original module and go to next step.
Page 442 8K - 4 WIPER AND WASHER SYSTEMS - XJ WINDSHIELD WASHER SYSTEM WITH NON-INTERMITTENT WIPE (1) Unplug washer pump connector. Measure resis- tance between terminal B at pump and a clean chas- sis ground. Meter should read zero ohms. If not OK, repair open to ground.
Page 443 WIPER AND WASHER SYSTEMS - XJ 8K - 5 gate wiper switch terminal C. Meter should read form as shown, replace faulty switch. battery voltage. If not OK, replace switch. (4) Remove liftgate cover and measure resistance from liftgate wiper motor terminal 1 to a good ground.
Page 444 8K - 6 WIPER AND WASHER SYSTEMS - XJ SERVICE PROCEDURES - XJ WINDSHIELD WIPER MOTOR REMOVE/INSTALL (1) Remove wiper arm assemblies by lifting blade off windshield and pulling out on the tab (Fig. 4) to lock wiper arm in up position. Fig.
Page 445 WIPER AND WASHER SYSTEMS - XJ 8K - 7 (4) Remove upper and lower column shrouds to gain access to the switch connector (Fig. 10). Fig. 8 Liftgate Wiper Motor Remove/Install (8) Remove the wiper motor mounting screws. (9) Remove the wiper motor. Fig.
Page 446 8K - 8 WIPER AND WASHER SYSTEMS - XJ Fig. 12 Steering Column Connectors Fig. 14 Liftgate Wiper/Washer Switch WASHER PUMP/RESERVOIR REMOVE/INSTALL LEFT-HAND DRIVE (1) Remove 2 washer reservoir attaching screws and 1 nut (Fig. 15). Fig. 13 Multi-Function Switch (12) Reverse removal procedures to install.
Page 447 WIPER AND WASHER SYSTEMS - XJ 8K - 9 Fig. 16 Washer Pumps (LHD) (2) Reservoir filler neck is held in reservoir by a grommet. Remove reservoir filler neck (Fig. 17) by pulling sharply away from reservoir. (3) Remove 2 reservoir mounting screws. (4) Raise vehicle on hoist and remove left front in- ner wheelhouse splash shield.
Page 448 8K - 10 WIPER AND WASHER SYSTEMS - YJ GENERAL INFORMATION - YJ Following are general descriptions of the major cleaning of the squeegees is suggested to remove de- components in the YJ (Wrangler) wiper and washer posits of salt and road film. The wiper blades, arms systems.
Page 449 WIPER AND WASHER SYSTEMS - YJ 8K - 11 The liftgate wiper motor can not be repaired. If WINDSHIELD WASHER NOZZLES faulty, the entire assembly must be replaced. The two fluidic washer nozzles are screwed into openings in the cowl panel below the windshield and WINDSHIELD WIPER/WASHER SWITCH are not adjustable.
Page 450 8K - 12 WIPER AND WASHER SYSTEMS - YJ DIAGNOSIS - YJ WINDSHIELD WIPER SYSTEM wiper switch as indicated in the tests below, and back probe wiper switch side of wiring harness con- (1) Remove circuit breaker from fuseblock module nector (black).
Page 451 WIPER AND WASHER SYSTEMS - YJ 8K - 13 OK, replace pump. If not OK, repair open between (b) Measure voltage at intermittent wipe module switch connector and pump connector. connector terminal B (to washer pump). Meter should read battery voltage. If not OK, replace in- WITH INTERMITTENT WIPE termittent wipe module.
Page 452 8K - 14 WIPER AND WASHER SYSTEMS - YJ NON-INTERMITTENT WIPE SWITCH TESTING...
Page 453 WIPER AND WASHER SYSTEMS - YJ 8K - 15 INTERMITTENT WIPE SWITCH TESTING...
Page 454 8K - 16 WIPER AND WASHER SYSTEMS - YJ LIFTGATE WIPER/WASHER SYSTEM (1) Turn ignition switch to ON and liftgate wiper/ washer switch to WASH. (a) Measure voltage at switch connector terminal P. Meter should read battery voltage. If not OK, check fuse 1.
Page 455 WIPER AND WASHER SYSTEMS - YJ 8K - 17 SERVICE PROCEDURES - YJ WINDSHIELD WIPER BLADE REMOVE/INSTALL (1) Rotate the wiper blade release (Fig. 3) clock- wise. This will release the wiper blade from the pivot pin. CAUTION: Take care to ensure that the wiper arm does not strike the windshield after the wiper blade has been removed.
Page 456 8K - 18 WIPER AND WASHER SYSTEMS - YJ Fig. 6 Liftgate Wiper Arm Remove/Install (2) Remove the nuts attaching the pivots to the windshield frame. (3) Remove the necessary hard or soft top compo- nents from the windshield frame. (4) Remove the windshield holddown bolts in the Fig.
Page 457 WIPER AND WASHER SYSTEMS - YJ 8K - 19 Fig. 12 Connect Drive Link To Pivot Shaft Fig. 10 Drive Link Remove (18) Raise windshield to upright position and in- stall left and right windshield holddown bolts. (19) Install nuts attaching pivots to windshield frame.
Page 458 8K - 20 WIPER AND WASHER SYSTEMS - YJ LIFTGATE WIPER MOTOR REMOVE/INSTALL (1) Remove wiper arm from motor (see Liftgate Wiper Arm Remove/Install). (2) Remove pivot shaft retaining nut. (3) Remove motor trim cover (Fig. 13). Fig. 15 Steering Wheel Remove/Install (4) Turn ignition switch to the LOCK position and remove the steering wheel nut and washer.
Page 459 WIPER AND WASHER SYSTEMS - YJ 8K - 21 Fig. 18 Instrument Bezel Remove/Install Fig. 16 Lockplate Remove Fig. 19 PRNDL Cable Clip Remove/Install Fig. 17 Turn/Hazard Switch and Dimmer Actuating (18) Remove cover under column. (19) If vehicle is equipped with a column shift, re- move PRNDL cable clip (Fig.
Page 460 8K - 22 WIPER AND WASHER SYSTEMS - YJ (20) Remove 2 nuts holding steering column bracket to brake sled (Fig. 20). Fig. 22 Turn/Hazard Switch and Steering Column Connectors Fig. 20 Lower Steering Column Mounting (26) Pry up locking tabs of steering column connec- (21) Remove 4 bolts holding steering column brace tor and remove connector from column bracket.
Page 461 WIPER AND WASHER SYSTEMS - YJ 8K - 23 (30) Remove key warning buzzer switch and re- (32) Remove screws that attach housing and taining clip with a paper clip inserted below retainer shroud assembly to column jacket and carefully re- so that retainer is flattened (Fig.
Page 462 8K - 24 WIPER AND WASHER SYSTEMS - YJ (36) Install a new switch and switch cover. (2) Remove the switch housing panel. (3) Unplug the switch connector. Slightly depress (37) Push on dimmer switch rod to make sure it is the switch mounting tabs and remove the switch connected then carefully position housing and shroud (Fig.
Page 463 WIPER AND WASHER SYSTEMS - YJ 8K - 25 (3) Remove the nut holding the nozzle to the glass. (4) Install the new washer nozzle. Fig. 31 Liftgate Washer Pump (2) Remove the washer hose from the back of the washer nozzle.
Page 465 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION—XJ VEHICLES ..18 INTERIOR LAMPS ..... . . 16 GENERAL INFORMATION .
Page 466 8L - 2 LAMPS—XJ VEHICLES HEADLAMP DIAGNOSIS...
Page 467 LAMPS—XJ VEHICLES 8L - 3 FOG LAMP DIAGNOSIS...
Page 468 8L - 4 LAMPS—XJ VEHICLES MULTI-FUNCTION SWITCH TESTING PROCEDURES—XJ The multi-function switch contains electrical cir- cuitry for: • Headlamp Dimmer Switch. • Passing Lights. • Turn Signals. • Hazard Warning. • Windshield Wiper. • Pulse Wiper. • Windshield Washer. This integrated switch is mounted to the left hand side of the steering column.
Page 469 LAMPS—XJ VEHICLES 8L - 5 (11) Refer to Service Procedures for assembly. Fig. 4 Steering Column Connectors Fig. 5 Dimmer Switch Continuity Chart (10) Use an ohmmeter to test for continuity be- tween the terminals of the switch as shown in the continuity chart (Fig.
Page 470 8L - 6 LAMPS—XJ VEHICLES SERVICE PROCEDURES INDEX page page Back-Up/Rear Turn Signal/Tail Lamp Bulb Headlamp Delay Function Trouble Diagnosis—XJ . 14 Replacement—XJ ..... . . 12 Headlamp Delay Module Replacement—XJ .
Page 471 LAMPS—XJ VEHICLES 8L - 7 (6) Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel. HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN—XJ ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicu- lar to a flat wall 7.62 meters (25 ft) away from front of headlamp lens (Fig.
Page 472 8L - 8 LAMPS—XJ VEHICLES Fig. 3 Fog Lamp Alignment —Typical (1) Remove the screws attaching the bezel to the lamp body (Fig. 5). Remove the bezel from the lamp body. (2) Remove the lens and reflector from the lamp body.
Page 473 LAMPS—XJ VEHICLES 8L - 9 FOG LAMP REPLACEMENT—XJ FRONT PARK/TURN SIGNAL LAMP BULB REPLACEMENT—XJ REMOVAL (1) Disconnect the fog lamp wire harness connector REMOVAL (Fig. 6). (1) Remove the headlamp bezel screw and the side marker lamp lens/housing screw (Fig. 8). Fig.
Page 474 8L - 10 LAMPS—XJ VEHICLES (3) Remove screws from the park/turn signal lamp housing (Fig. 10). Fig. 10 Park/Turn Signal Lamp Housing Removal Fig. 11 Side Marker Lamp (4) Separate the lamp housing from the headlamp HEADLAMP SWITCH—XJ bezel. To remove or replace the headlamp switch. Refer to (5) Rotate the bulb socket one-third turn and re- Group 8E, Instrument Panel and Gauges.
Page 475 LAMPS—XJ VEHICLES 8L - 11 INSTALLATION (1) Squeeze the tabs on the side of the fog lamp switch and insert the switch in the instrument panel cavity. (2) Connect the wire harness connector to the switch. (3) Install the fog lamp switch cover. (4) Position the bezel on the instrument panel and install the attaching screws.
Page 476 8L - 12 LAMPS—XJ VEHICLES BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB LICENSE PLATE LAMP—XJ REPLACEMENT—XJ REMOVAL (1) Remove screws and the license plate lamp visor REMOVAL from the liftgate (Fig. 18). (1) Remove the tail lamp housing upper retaining screws (Fig. 16). Slide the lamp housing upward off the lower screw while tipping the top of the lamp away from the body and separate it from the rear of the vehicle.
Page 477 LAMPS—XJ VEHICLES 8L - 13 Fig. 19 Center High Mounted Stop Lamp (CHMSL) Fig. 21 Replacing CHMSL Bulb Assembly Fig. 22 Underhood Lamp INSTALLATION (1) Insert a replacement bulb in the lamp base socket and rotate it clockwise. (2) Connect the wire harness connector to the lamp.
Page 478 8L - 14 LAMPS—XJ VEHICLES (2) Remove the screw that attaches the module to the inside of the instrument panel. (3) Disconnect the wire harness connector and re- move the module from the instrument panel. INSTALLATION (1) Position the module inside the I/P and connect the wire harness connector to the module.
Page 479 LAMPS—XJ VEHICLES 8L - 15 DAYTIME RUNNING LIGHTS (CANADA ONLY)—XJ SERVICE INFORMATION The Daytime Running Lights (Headlamps) System is installed on vehicles manufactured for sale in Can- ada only. The headlamps are illuminated when the ignition switch is turned to the ON position. The DRL module receives a vehicle-moving signal from the vehicle speed sensor.
Page 480 8L - 16 LAMPS—XJ VEHICLES INTERIOR LAMPS INDEX page page Dome Lamp Replacement—XJ ....17 Lighted Vanity Mirror Trouble Diagnosis—XJ ..16 Dome/Courtesy Lamp Service Information—XJ .
Page 481 LAMPS—XJ VEHICLES 8L - 17 DOME LAMP REPLACEMENT—XJ OVERHEAD CONSOLE—XJ MAP READING LAMP LENS REMOVAL REMOVAL (1) Make a straight hook at the end of a large pa- (1) Remove the dome lamp lens by squeezing it at per clip or wire (approximately 1.5-mm/0.06-in diam- both sides.
Page 482 8L - 18 LAMPS—XJ VEHICLES BULB APPLICATION—XJ VEHICLES GENERAL INFORMATION Glove Compartment..........194 Overhead Console ..........912 The following Bulb Application Table lists the lamp Under Hood ............105 title on the left side of the column and trade number Vanity Mirror ............74 or part number on the right.
Page 483 LAMPS—YJ VEHICLES 8L - 19 LAMPS CONTENTS page page BULB APPLICATION—YJ VEHICLES ..32 INTERIOR LAMPS ..... . . 31 GENERAL INFORMATION .
Page 484 8L - 20 LAMPS—YJ VEHICLES HEADLAMP DIAGNOSIS...
Page 485 LAMPS—YJ VEHICLES 8L - 21 FOG LAMP DIAGNOSIS...
Page 486 8L - 22 LAMPS—YJ VEHICLES SERVICE PROCEDURES INDEX page page Back-Up/Rear Turn Signal/Tail Lamp Bulb Headlamp Alignment—YJ ....22 Replacement—YJ ..... . . 28 Headlamp Bulb Replacement—YJ .
Page 487 LAMPS—YJ VEHICLES 8L - 23 HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN—YJ ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicu- lar to a flat wall 7.62 meters (25 ft) away from front of headlamp lens (Fig. 1). (2) If necessary, tape a line on the floor 7.62 meters (25 ft) away from and parallel to the wall.
Page 488 8L - 24 LAMPS—YJ VEHICLES Fig. 3 Fog Lamp Alignment—Typical Fig. 5 Fog Lamp (2) Install the bulb holder in the lens/reflector. (3) Position the stone shield and reflector on the lamp housing. Install the screws that attach the stone shield and the reflector to the lamp housing. Tighten the screws securely.
Page 489 LAMPS—YJ VEHICLES 8L - 25 FOG LAMP REPLACEMENT—YJ REMOVAL (1) Disconnect the fog lamp wire harness connec- tor. (2) Remove the fog lamp nut(s), washers(s) and bolt(s) from the support bracket (Fig. 5 and 6). Fig. 7 Park/Turn Signal Lamp Bulb Replacement SIDE MARKER LAMP BULB REPLACEMENT—YJ Fig.
Page 490 8L - 26 LAMPS—YJ VEHICLES HEADLAMP SWITCH—YJ To remove or replace the headlamp switch, refer to Group 8E, Instrument Panel and Gauges. FOG LAMP SWITCH REPLACEMENT—YJ REMOVAL The fog lamp switch is located on the instrument panel at the right of the steering column. The fog lamp circuit relay is located below the left headlamp.
Page 491 LAMPS—YJ VEHICLES 8L - 27 Fig. 13 A/C Evaporator Housing • Compress the switch and insert a 3/32-inch diam- eter drill bit into the adjustment hole (Fig. 14). • The drill bit will prevent any horizontal movement of the switch. Fig.
Page 492 8L - 28 LAMPS—YJ VEHICLES (9) Raise and support the A/C evaporator housing (Fig. 13). (10) Install the evaporator housing-to-instrument panel screws and evaporator support bracket screw. BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB REPLACEMENT—YJ REMOVAL (1) Remove the lens retaining screws from the tail lamp housing (Fig.
Page 493 LAMPS—YJ VEHICLES 8L - 29 Fig. 19 Underhood Lamp Fig. 17 Removing CHMSL Access Door Fig. 20 Underhood Lamp Components INSTALLATION (1) Insert a replacement bulb in the lamp base socket and rotate it clockwise. (2) Connect the wire harness connector to the lamp.
Page 494 8L - 30 LAMPS—YJ VEHICLES (3) Insert a replacement bulb in the lamp base (4) Remove the module from the fender inner socket and rotate it clockwise. panel. (4) Connect the wire harness connector to the INSTALLATION lamp. (1) Position the DRL module on the left, fender in- DAYTIME RUNNING LIGHTS (CANADA ONLY)—YJ ner panel.
Page 495 LAMPS—YJ VEHICLES 8L - 31 INTERIOR LAMPS INDEX page page Dome/Courtesy Lamp Service Information—YJ . . . 31 Hardtop Dome/Cargo Lamp Bulb Replacement—YJ Dome/Courtesy Lamp Trouble Diagnosis—YJ ..31 Vehicles ....... 31 DOME/COURTESY LAMP SERVICE (2) If not, check for an open circuit in black (ground) wire.
Page 496 8L - 32 LAMPS—YJ VEHICLES BULB APPLICATION—YJ VEHICLES GENERAL INFORMATION Dome/Cargo ............212-2 Glove Compartment..........194 The following Bulb Application Table lists the lamp Under Hood ............105 title on the left side of the column and trade number Underpanel Courtesy..........89 or part number on the right. CAUTION: Do not use bulbs that have a higher can- INDICATOR LAMPS dle power than the bulb listed in the Bulb Applica-...
Page 497 GENERAL INFORMATION The airbag system is a standard equipment safety AIRBAG MODULE device on XJ (Cherokee) models. It is designed to pro- The airbag module protective cover is the only vis- tect the driver from serious injury, caused by a fron- ible part of the system.
Page 498 8M - 2 RESTRAINT SYSTEMS the airbag cushion so it can discharge the gas it pro- The D-shaft retains two spring-loaded firing pins. duces directly into the cushion. The protective cover When a firing pin is released by the D-shaft, it is fitted to the front of the airbag module and forms strikes and ignites a primer.
Page 499 RESTRAINT SYSTEMS 8M - 3 DEPLOYED Following an airbag deployment, the vehicle inte- rior will contain a powdery residue. This residue is primarily sodium bicarbonate (baking soda), used as an airbag cushion lubricant. However, there will also be traces of sodium hydroxide powder, a chemical byproduct of the generant used for airbag deploy- ment.
Page 500 8M - 4 RESTRAINT SYSTEMS Fig. 3 Airbag Module Remove/Install...
Page 501 The electrically-heated rear window defogger is an A repair kit is available to repair the grid lines and available option on XJ (Cherokee), and YJ (Wrangler) bus bars, or to reinstall the heated glass pigtail models equipped with the hardtop roof option. Fol- wires.
Page 502 8N - 2 REAR WINDOW DEFOGGER • relay/timer nal B (driver side) with the positive lead. The volt- • rear window grid lines (all grid lines would have meter should read 10-14 volts. to be broken or one of the feed wires disconnected for the entire system to be inoperative).
Page 503 REAR WINDOW DEFOGGER 8N - 3 DEFOGGER SWITCH (2) Measure voltage at relay connector terminal 5. The meter should read battery voltage. If OK, go to With defogger switch connector separated from de- next step. If not OK, repair open from fuse 8 (XJ), or fogger switch;...
Page 504 8N - 4 REAR WINDOW DEFOGGER (9) Allow epoxy to cure 24 hours at room tempera- ture or use heat gun with a 260°-371°C (500°-700°F) range for 15 minutes. Hold gun approximately 254mm (10 inches) from repaired area. (10) After conductive epoxy is properly cured re- move wedge or clamp from terminal or pigtail and check operation of rear window defogger.
Page 505 POWER LOCKS 8P - 1 POWER LOCKS CONTENTS page page DIAGNOSIS ......2 SERVICE PROCEDURES .
Page 506 8P - 2 POWER LOCKS DIAGNOSIS As a preliminary system diagnosis, note system op- eration while you actuate both the Lock and Unlock functions with the power lock switches and the key- less entry transmitter. Then, proceed as follows: • If system fails to function with either the switches or the transmitter, see Power Lock System diagnosis.
Page 507 POWER LOCKS 8P - 3 DRIVER’S POWER LOCK SWITCH—2-DOOR (LHD)
Page 508 8P - 4 POWER LOCKS DRIVER’S POWER LOCK SWITCH—2-DOOR (RHD)
Page 509 POWER LOCKS 8P - 5 DRIVER’S POWER LOCK SWITCH—4-DOOR...
Page 510 8P - 6 POWER LOCKS PASSENGER’S POWER LOCK SWITCH...
Page 511 POWER LOCKS 8P - 7 POWER LOCK MOTOR KEYLESS ENTRY MODULE (1) Once it is determined which lock motor is inop- (1) Check fuse 9 in fuseblock module. If OK, go to erative, that motor can be tested. Disconnect the wire next step.
Page 512 8P - 8 POWER LOCKS SERVICE PROCEDURES KEYLESS ENTRY TRANSMITTER programmed into the module. Within 20 seconds of the previous transmitter programming, move the me- To replace transmitter batteries, separate transmit- chanical door lock lever to the LOCK position. Aim ter case by prying gently with a trim stick or other another transmitter at the receiver dome and press wide flat-bladed tool at center seam (Fig.
Page 513 POWER LOCKS 8P - 9 Fig. 7 Trim Panel Remove Fig. 5 Power Lock Switch Remove (4) Remove armrest lower retaining screws. (5) Swing armrest downward to a vertical position. This is necessary to disconnect armrest from upper retainer clip (Fig. 6). Fig.
Page 514 8P - 10 POWER LOCKS Fig. 12 Latch Assembly Remove/Install Fig. 9 Motor Remove/Install (7) Reverse removal procedures to install. Tighten latch screws to 9 N m (7 ft. lbs.). KEYLESS ENTRY MODULE REMOVE/INSTALL WITHOUT OVERHEAD CONSOLE (1) Remove 2 screws attaching receiver housing to headlining (Fig.
Page 515 POWER LOCKS 8P - 11 (5) Reverse removal procedures to install. WITH OVERHEAD CONSOLE (1) Remove screw forward of compass unit (Fig. 14). Fig. 16 Disconnect Wire Harnesses Fig. 14 Remove/Install Overhead Console (2) Flex housing outward while pressing upward to disengage housing from the rear bracket (arrow 1) (Fig.
Page 516 8P - 12 POWER LOCKS (8) Reverse removal procedures to install. Be sure to flex housing outward near the keyless entry mod- ule until the console snaps onto the rear mounting bracket. POWER LOCK/UNLOCK RELAY REMOVE/INSTALL The power lock/unlock relays are located in the re- lay center.
Page 517 ....1 GENERAL INFORMATION A six-way driver’s side power seat is an available option on XJ (Cherokee) models. The power seat sys- tem receives battery feed through fuse 6 in the power distribution center and circuit breaker 16 in the fuse- block module at all times.
Page 518 8R - 2 POWER SEATS DIAGNOSIS Before any testing is attempted the battery should (3) Check for continuity between black wire at be fully charged and all connections and pins cleaned switch connector and a good ground. There should be and tightened to ensure proper continuity and continuity.
Page 519 POWER SEATS 8R - 3 SERVICE PROCEDURES POWER SEAT SWITCH REMOVE/INSTALL POWER SEAT ADJUSTER/MOTORS REMOVE/ INSTALL (1) Disconnect battery negative cable. (2) Reach under seat and release switch and bezel (1) Disconnect battery negative cable. (2) Remove 4 bolts securing seat adjuster to floor retainer snap clips (Fig.
Page 521 Power door windows are optional equipment on XJ ing mechanism. A positive and negative battery con- (Cherokee) models. The power windows operate only nection to the two motor terminals will cause the with the ignition switch in the ON position. This motor to rotate in one direction.
Page 522 8S - 2 POWER WINDOWS has battery voltage, circuit breaker is faulty and OFF, LOCK, UP and DOWN switch positions. If OK, must be replaced. If neither terminal has battery go to Power Window Motor diagnosis. If not OK, re- voltage, repair circuit from ignition switch as re- place the switch.
Page 523 POWER WINDOWS 8S - 3 DRIVER’S POWER WINDOW SWITCH—4-DOOR...
Page 524 8S - 4 POWER WINDOWS DRIVER’S POWER WINDOW SWITCH—2-DOOR (LHD)
Page 525 POWER WINDOWS 8S - 5 DRIVER’S POWER WINDOW SWITCH—2-DOOR (RHD)
Page 526 8S - 6 POWER WINDOWS PASSENGER’S POWER WINDOW SWITCH...
Page 527 POWER WINDOWS 8S - 7 SERVICE PROCEDURES POWER WINDOW SWITCH REMOVE/INSTALL (5) To install switch, position switch and press in retainer clips until they snap into position. Reverse (1) Remove the interior door latch release assem- remaining removal procedures to complete installa- bly and control panel retaining screws (Fig.
Page 528 8S - 8 POWER WINDOWS Fig. 4 Trim Panel Remove/Install Fig. 6 Remove/Install Glass Attaching Screw (15) Remove remaining window regulator attach- ing screws (Fig. 5). (16) Remove window regulator. (17) To install, place regulator inside door. (18) Attach regulator to door using screws or the hardware kit supplied with a new regulator.
Page 529 GENERAL INFORMATION Power outside rear view mirrors are an available ponent of the mirror unit is faulty or damaged, the option on XJ (Cherokee) models. Following are gen- entire assembly must be replaced. eral descriptions of the major components in the POWER MIRROR SWITCH power mirror system.
Page 530 8T - 2 POWER MIRRORS POWER MIRROR SWITCH...
Page 531 POWER MIRRORS 8T - 3 POWER MIRROR SWITCH CONTINUITY (LEFT POSITION) POWER MIRROR SWITCH CONTINUITY (RIGHT POSITION)
Page 532 8T - 4 POWER MIRRORS SERVICE PROCEDURES POWER MIRROR SWITCH REMOVE/INSTALL (2) Disconnect control linkage and wire harness connector. (1) Disconnect battery negative cable. (3) Remove latch release and control panel assem- (2) Using a wide flat-bladed tool, pry the switch bly.
Page 533 POWER MIRRORS 8T - 5 (8) Remove screw holding mirror trim cover (Fig. (9) Disconnect power mirror wire harness at con- nector in door. (10) Pull harness up through door. (11) Remove 3 screws holding mirror to door (Fig. Fig. 5 Power Mirror Trim Cover Fig.
Page 535 ....1 GENERAL INFORMATION This group covers the buzzer warning system, IGNITION KEY-IN SWITCH which is standard equipment on XJ (Cherokee)/YJ XJ MODELS (Wrangler) models. The system provides an audible The key-in switch is integral to the ignition switch,...
Page 536 8U - 2 CHIME/BUZZER WARNING SYSTEMS DIAGNOSIS BUZZER MODULE (1) Check fuses (15 and 17 - XJ, 3 and 9 - YJ) in the fuseblock module. If fuses are OK, go to next step. If not OK, replace fuses as required. (2) Check for battery voltage at fuse (15 - XJ, 3 - YJ) in fuseblock module.
Page 537 CHIME/BUZZER WARNING SYSTEMS 8U - 3 HEADLAMP SWITCH (XJ ONLY) (1) Remove headlamp switch from instrument panel (refer to Group 8E - Instrument Panel and Gauges for procedure). Unplug headlamp switch con- nector. Open driver’s door. Check for continuity be- tween headlamp switch connector cavity with light blue wire and a good ground.
Page 538 8U - 4 CHIME/BUZZER WARNING SYSTEMS BUZZER MODULE SCHEMATIC - XJ BUZZER MODULE SCHEMATIC - YJ SERVICE PROCEDURES • ignition key-in switch (YJ) - refer to Group 19 - Service procedures for components of the buzzer system can be found in the appropriate group as fol- Steering •...
Page 539 WIRING DIAGRAMS—GENERAL INFORMATION 8W - 1 WIRING DIAGRAMS—GENERAL INFORMATION INDEX page page Circuit Identification ......1 Symbols .
Page 540 8W - 2 WIRING DIAGRAMS—GENERAL INFORMATION Fig. 1 Wire Color Code Identification Fig. 3 Circuit Identification Fig. 2 Wire Color Code Chart Fig. 4 Connector Identification CONNECTORS TAKE OUTS Connectors shown in the diagrams are identified The abbreviation T/O is used in the component using the international standard arrows for male and location section to indicate a point in which the wir- female terminals (Fig.
Page 541 WIRING DIAGRAMS—GENERAL INFORMATION 8W - 3 Fig. 5 Symbol Identification...
Page 542 8W - 4 WIRING DIAGRAMS—GENERAL INFORMATION the following procedures to reduce the possibility of CAUTION: - Most of the electrical components used electrostatic charge build up on the body and inad- in today’s vehicle are Solid State. When checking vertent discharge into the component. If it is not resistance in these circuits use a meter with a 10- known whether the part is ESD sensitive, assume megohm or greater impedance.
Page 543 WIRING DIAGRAMS—GENERAL INFORMATION 8W - 5 (2) Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropri- ate test procedure. Fig. 9 Testing for Continuity (4) Start connecting the items in the fuse circuit one at a time.
Page 544 8W - 6 WIRING DIAGRAMS—GENERAL INFORMATION Fig. 10 Testing for Voltage Drop Fig. 11 Wire Repair WIRING REPAIR When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
Page 545 WIRING DIAGRAMS—GENERAL INFORMATION 8W - 7 Fig. 15 Terminal Removal Fig. 13 Using Special Tool 6742 Fig. 16 Terminal Removal Using Special Tool Fig. 14 Connector Locking Wedge Tab (Typical) (5) Remove 1 inch of insulation from each wire on (5) Reset the terminal locking tang, if it has one.
Page 546 8W - 8 WIRING DIAGRAMS—GENERAL INFORMATION (13) Solder the connection together using rosin core type solder only. Do not use acid core solder. (14) Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
Page 547 WIRING DIAGRAMS—XJ VEHICLES 8W - 1 - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION—WIRING 8W-48 HEATED REAR WINDOW ..8W-48-1 DIAGRAMS ....8W-01-1 8W-49 OVERHEAD CONSOLE .
Page 549 8W-10 FUSE/FUSE BLOCK—XJ VEHICLES 8W - 10 - 1 FUSE/FUSE BLOCK GENERAL INFORMATION DIAGRAM INDEX This section covers the Fuse Block and all circuits Component Page involved with it. For additional information on sys- tem operation, refer to the appropriate section of the ABS Control Module .
Page 561 8W-11 POWER DISTRIBUTION—XJ VEHICLES 8W - 11 - 1 POWER DISTRIBUTION GENERAL INFORMATION This section covers the Power Distribution Center (PDC) and all circuits involved with it. For additional information on system operation, refer to the appro- priate section of the wiring diagrams. DIAGRAM INDEX Component Page...
Page 579 8W-15 GROUND DISTRIBUTION—XJ VEHICLES 8W - 15 - 1 GROUND DISTRIBUTION GENERAL INFORMATION DIAGRAM INDEX This section identifies the vehicle grounds, splices Component Page connected to each ground, and the components con- nected to each ground. Refer to the appropriate sec- G101 .
Page 585 8W-20 CHARGING SYSTEM—XJ VEHICLES 8W - 20 - 1 CHARGING SYSTEM CHARGING SYSTEM HELPFUL INFORMATION • If the vehicle is equipped with a 2.5L engine, cir- The charging system is an integral part of the bat- cuit Z0 also connects to the battery. tery and starting systems.
Page 589 8W-21 STARTING SYSTEM—XJ VEHICLES 8W - 21 - 1 STARTING SYSTEM INDEX page page Diagram Index ......1 Starting System .
Page 593 8W-30 FUEL/IGNITION—XJ VEHICLES 8W - 30 - 1 FUEL/IGNITION INDEX page page Automatic Shut Down (ASD) Relay ... . . 1 Idle Air Control (IAC) Motor ....2 Battery Feed .
Page 594 8W - 30 - 2 8W-30 FUEL/IGNITION—XJ VEHICLES • Circuit A141 also supplies battery voltage to the cuit A142 supplies voltage to the fuel injectors. Each injector has a separate ground circuit controlled by heated oxygen sensor. the PCM. FUEL PUMP MODULE Circuit K11 provides ground for injector number one.
Page 595 8W-30 FUEL/IGNITION—XJ VEHICLES 8W - 30 - 3 Circuit G7 from the vehicle speed sensor provides The PCM receives the camshaft position sensor sig- an input signal to the PCM. The G7 circuit connects nal on circuit K44. Circuit K44 connects to cavity 44 to cavity 47 of the PCM.
Page 596 8W - 30 - 4 8W-30 FUEL/IGNITION—XJ VEHICLES The PCM provides a ground for the engine coolant HELPFUL INFORMATION temperature sensor signal (circuit K2) through circuit Refer to Group 14 for MAP sensor operation. K4. Circuit K4 connects to cavity 4 of the PCM con- Circuit K6 splices to supply 5 volts to the throttle nector.
Page 597 8W-30 FUEL/IGNITION—XJ VEHICLES 8W - 30 - 5 Circuit T17 from fuse 3 in the power distribution HELPFUL INFORMATION • Circuit Z1 also supplies a ground for the PCM center supplies voltage to the coil and contact sides of the TCC relay. When the PCM provides a ground high current drivers.
Page 598 8W - 30 - 6 8W-30 FUEL/IGNITION—XJ VEHICLES DIAGRAM INDEX—2.5L ENGINE DIAGRAM INDEX—4.0L ENGINE Component Page Component Page Automatic Shut Down Relay ....8W-30-8 Automatic Shut Down Relay ....8W-30-14 Camshaft Position Sensor .
Page 604 1995 Jeep Cherokee/Wrangler Publication No. 81-370-5146 TSB 26-07-95 September, 1995...
Page 610 1995 Jeep Cherokee/Wrangler Publication No. 81-370-5146 TSB 26-07-95 September, 1995...
Page 613 8W-31 TRANSMISSION CONTROLS—XJ VEHICLES 8W - 31 - 1 TRANSMISSION CONTROLS UPSHIFT LAMP TORQUE CONVERTER CLUTCH (TCC) SOLENOID AND RELAY—2.5L ENGINE ONLY On vehicles equipped with a manual transmission, the PCM grounds the up-shift lamp on circuit K54. The TCC solenoid is only used on 2.5L engines with the three-speed automatic transmissions.
Page 617 8W-32 ANTI-LOCK BRAKES—XJ VEHICLES 8W - 32 - 1 ANTI-LOCK BRAKES INDEX page page ABS Power Relay ......1 Diagram Index .
Page 618 8W - 32 - 2 8W-32 ANTI-LOCK BRAKES—XJ VEHICLES ABS pump motor relay. The ABS control module pro- For the right front decay solenoid, the ABS module vides ground for the relay on circuit B116. Circuit provides a ground path on circuit B248. Circuit B248 B116 connects to cavity 15 of the ABS control mod- connects to cavity 21 of the ABS control module.
Page 619 8W-32 ANTI-LOCK BRAKES—XJ VEHICLES 8W - 32 - 3 DIAGRAM INDEX Component Page ABS Control Module ....8W-32-4 thru 8 ABS Hydraulic Unit ..... . .8W-32-6 ABS Power Relay .
Page 624 1995 Jeep Cherokee/Wrangler Publication No. 81-370-5146 TSB 26-07-95 September, 1995...
Page 625 8W-33 VEHICLE SPEED CONTROL—XJ VEHICLES 8W - 33 - 1 VEHICLE SPEED CONTROL VEHICLE SPEED CONTROL HELPFUL INFORMATION • Circuit K29 also connects to the ABS control mod- The vehicle speed control system is operated by the ule on vehicles with all wheel anti-lock brakes. Powertrain Control Module (PCM).
Page 629 8W-40 INSTRUMENT CLUSTER—XJ VEHICLES 8W - 40 - 1 INSTRUMENT CLUSTER INDEX page page ABS Warning Lamp ......2 Low Fuel Warning Lamp .
Page 630 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER—XJ VEHICLES OIL PRESSURE GAUGE provides voltage for the lamp. The MIL displays the message CHECK ENGINE when illuminated. The case grounded oil pressure sensor is a variable For information regarding diagnostic trouble code resistor that connects to circuit G6.
Page 631 8W-40 INSTRUMENT CLUSTER—XJ VEHICLES 8W - 40 - 3 CHARGING SYSTEM INDICATOR LAMP DIAGRAM INDEX The Powertrain Control Module (PCM) illuminates the charging system indicator lamp by providing Component Page ground for the lamp on circuit G12. Circuit G12 con- 4WD Switch .
Page 639 8W-41 HORN/CIGAR LIGHTER—XJ VEHICLES 8W - 41 - 1 HORN/CIGAR LIGHTER HORN CIGAR LIGHTER In the ACCESSORY or RUN position, the ignition The horn system uses two switches and horn relay. switch supplies voltage to fuse 2 in the fuse block on The horn switches are on the steering wheel.
Page 643 8W-42 AIR CONDITIONING/HEATER—XJ VEHICLES 8W - 42 - 1 AIR CONDITIONING/HEATER CONTENTS page page A/C-HEATER SYSTEM ..... . 1 HEATER SYSTEM ......1 GENERAL INFORMATION This section of the wiring diagrams is divided into two sub-sections;...
Page 644 8W - 42 - 2 8W-42 AIR CONDITIONING/HEATER—XJ VEHICLES In the M2 position, the blower motor supplies volt- RADIATOR FAN RELAY AND MOTOR age to the resistor block on circuit C6. From circuit In the START or RUN positions, the ignition C6 voltage flows through two resistors to the blower switch connects circuit A1 from fuse 6 in the Power motor on circuit C1.
Page 649 8W-44 INTERIOR LIGHTING—XJ VEHICLES 8W - 44 - 1 INTERIOR LIGHTING INDEX page page Cargo Lamp, Courtesy Lamps and Dome Lamp ..1 Instrument Panel Illumination Lamps ... . 1 Chime/Buzzer Module .
Page 650 8W - 44 - 2 8W-44 INTERIOR LIGHTING—XJ VEHICLES READING LAMPS the chime/buzzer is supplied through the key-in switch. The ground path is over circuit M11, through Circuit M1 from the IOD fuse (fuse F9) in the fuse the closed key-in switch to circuit C26. From circuit block supplies power to the reading lamps.
Page 661 8W-47 AUDIO SYSTEM—XJ VEHICLES 8W -47 - 1 AUDIO SYSTEM RADIO Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the When the ignition switch is in the ACCESSORY or radio.
Page 669 8W-48 HEATED REAR WINDOW—XJ VEHICLES 8W - 48 - 1 HEATED REAR WINDOW HEATED REAR WINDOW HELPFUL INFORMATION • When the ignition switch is in the ACCESSORY or The heated rear window relay supplies power to RUN positions, it connects circuit A1 from fuse 6 in heated rear window grid.
Page 673 8W-49 OVERHEAD CONSOLE—XJ VEHICLES 8W - 49 - 1 OVERHEAD CONSOLE OVERHEAD CONSOLE LAMPS Circuit M1 supplies voltage for the case grounded When the ignition switch is in the START or RUN reading lamps in the overhead console. The ignition position, it connects circuit A1 from fuse 6 in the off draw (IOD) fuse (fuse 9) in the fuse block supplies Power Distribution Center (PDC) to circuit A21.
Page 677 8W-50 FRONT LIGHTING—XJ VEHICLES 8W - 50 - 1 FRONT LIGHTING INDEX page page Daytime Running Lamp (DRL) Module ... 2 Headlamp Delay Module ..... 2 Diagram Index .
Page 678 8W - 50 - 2 8W-50 FRONT LIGHTING—XJ VEHICLES Circuit L39 supplies voltage to the fog lamps. Cir- The DRL module receives the vehicle speed sensor input from circuit G7. Circuit G465 from the DRL cuit Z1 provides ground for the fog lamps. module splices to circuit L3 to provide power for the If the high beam lamps are ON, circuit G465 ener- high beam indicator lamp in the instrument cluster.
Page 687 8W-51 REAR LIGHTING—XJ VEHICLES 8W - 51 - 1 REAR LIGHTING TAIL LAMPS AND REAR LICENSE PLATE LAMPS BACK-UP LAMPS Circuit A3 from fuse 5 in the Power Distribution In the START or RUN position, the ignition switch Center (PDC) connects to a bus bar in the fuse block connects circuit A1 from fuse 6 in the Power Distri- which feeds circuit L7.
Page 693 8W-52 TURN SIGNALS—XJ VEHICLES 8W - 52 - 1 TURN SIGNALS COMBINATION FLASHER HELPFUL INFORMATION • The turn signal lamps are the same lamps used In the ACCESSORY or RUN position, the ignition for the hazard flasher. switch connects circuit A1 from fuse 6 in the Power •...
Page 697 8W-53 WIPERS—XJ VEHICLES 8W - 53 - 1 WIPERS INDEX page page Diagram Index ......2 Wipers—Intermittent .
Page 698 8W - 53 - 2 8W-53 WIPERS—XJ VEHICLES In the WIPE or WASH positions, the rear wiper DIAGRAM INDEX switch supplies voltage to the wiper motor on circuit V13. Circuit Z1 provides ground for the wiper motor. Component Page The rear windshield washer uses a pump motor lo- Circuit Breaker .
Page 703 8W-54 TRAILER TOW—XJ VEHICLES 8W - 54 - 1 TRAILER TOW TRAILER TOW LEFT TURN RELAY The factory installed trailer tow system in this ve- Power for the coil side of the left turn relay is sup- hicle uses three relays and a circuit breaker along plied by circuit L61.
Page 707 8W-60 POWER WINDOWS—XJ VEHICLES 8W - 60 - 1 POWER WINDOWS INDEX page page Diagram Index ......2 Power Windows .
Page 708 8W - 60 - 2 8W-60 POWER WINDOWS—XJ VEHICLES through this switch to circuit Q22. The Q22 circuit HELPFUL INFORMATION then goes to the right rear window motor. • When the ignition switch is in the RUN position, it Ground for the window motor is supplied on the connects circuit A1 from fuse 11 in the Power Distri- Q12 circuit back to the right rear door switch.
Page 711 8W-61 POWER DOOR LOCKS—XJ VEHICLES 8W - 61 - 1 POWER DOOR LOCKS POWER DOOR LOCKS REMOTE KEYLESS ENTRY MODULE Two relays provide power for the power door lock Circuit M1 from the ignition off draw (IOD) fuse in motors. The Unlock relay provides power for the un- cavity 9 of the fuse block supplies power to the Re- lock circuits while the Lock relay powers the lock cir- mote Keyless Entry (RKE) module.
Page 717 8W-62 POWER MIRRORS—XJ VEHICLES 8W - 62 - 1 POWER MIRRORS POWER MIRRORS LEFT POWER MIRROR OPERATION In the left position, the power mirror switch sup- Four switches operates the left and right power plies power to the left mirror LEFT/RIGHT motor on mirrors.
Page 719 8W-63 POWER SEAT—XJ VEHICLES 8W - 63 - 1 POWER SEAT POWER SEAT through the closed contacts in the switch to the S1 circuit. The S1 circuit connects to the motor. Ground Battery voltage for the power seat system is sup- is provided on the S2 circuit back to the switch.
Page 721 8W-70 SPLICE INFORMATION—XJ VEHICLES 8W - 70 - 1 SPLICE INFORMATION GENERAL INFORMATION This section identifies all splices in the wiring dia- grams. It also shows the splices in their entirety. All circuits that are part of the splices are shown, and the systems they affect are referenced.
Page 747 8W-80 CONNECTOR PIN OUTS—XJ VEHICLES 8W - 80 - 1 CONNECTOR PIN OUTS GENERAL INFORMATION circuit occupies. Individual connector numbers are referenced on diagram pages throughout Group 8W. The pages referenced in this section show the con- nector, the circuits in the connector, and the pin that CONNECTOR LOCATIONS Component Page...
Page 748 8W - 80 - 2 8W-80 CONNECTOR PIN OUTS—XJ VEHICLES Component Page Component Page C232 ....... .8W-80-28 C342 .
Page 751 1995 Jeep Cherokee/Wrangler Publication No. 81-370-5146 TSB 26-07-95 September, 1995...
Page 754 1995 Jeep Cherokee/Wrangler Publication No. 81-370-5146 TSB 26-07-95 September, 1995...
Page 797 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 1 CONNECTOR LOCATIONS GENERAL INFORMATION nector index is provided. Use the wiring diagrams in each section for connector number identification. Re- This section provides illustrations identifying com- fer to the index for the proper figure number. ponent and connector locations in the vehicle.
Page 798 8W - 90 - 2 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES Connector # Color Location Fig. Connector # Color Location Fig. C226 ..BK . . . Left Kick Panel C342 ..BK . . . Front Center of Roof Liner ..16 C227 .
Page 799 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 3 Connector # Color Location Fig. Connector # Color Location Fig. G108 ... . Right Rear of Engine ..6, 7 G201 .
Page 800 8W - 90 - 4 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 801 Fig. 2 Engine Compartment Wiring Connectors—4.0L...
Page 802 Fig. 3 Engine Compartment Wiring Connectors...
Page 803 Fig. 4 Engine Compartment Wiring Connectors—Right Side, 4.0L...
Page 804 8W - 90 - 8 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 805 Fig. 6 Engine Wiring Connectors—2.5L Engine...
Page 806 Fig. 7 Engine Wiring Connectors—4.0L Engine...
Page 807 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 11 Fig. 8 Front End Lighting Wiring Connectors Fig. 9 Instrument Panel Ground...
Page 808 8W - 90 - 12 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 809 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 13...
Page 810 Fig. 12 Instrument Panel Wiring Connectors...
Page 811 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 15...
Page 812 8W - 90 - 16 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 813 Fig. 15 Body Wiring Connectors...
Page 814 8W - 90 - 18 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 815 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 19...
Page 816 8W - 90 - 20 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 817 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 21 Fig. 19 ABS Sensors Wiring Connections Fig. 20 Rear Compartment Wiring Connectors...
Page 818 8W - 90 - 22 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES...
Page 819 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES 8W - 90 - 23 Fig. 22 Trailer Tow Connector Fig. 23 Power Seat Wiring Connectors...
Page 820 8W - 90 - 24 8W-90 CONNECTOR LOCATIONS—XJ VEHICLES Fig. 24 Liftgate Wiring Connector Fig. 25 Center High Mounted Stop Lamps (CHMSL)
Page 821 8W-95 SPLICE LOCATIONS—XJ VEHICLES 8W - 95 - 1 SPLICE LOCATIONS GENERAL INFORMATION This section provides illustrations identifying the general location of the splices in this vehicle. A splice index is provided. Use the wiring diagrams in each section for splice number identification. Refer to the index for the proper splice number.
Page 822 8W - 95 - 2 8W-95 SPLICE LOCATIONS—XJ VEHICLES...
Page 823 8W-95 SPLICE LOCATIONS—XJ VEHICLES 8W - 95 - 3 Fig. 2 Engine Compartment Splices XJ Fig. 3 Front End Splices XJ...
Page 824 8W - 95 - 4 8W-95 SPLICE LOCATIONS—XJ VEHICLES...
Page 825 8W-95 SPLICE LOCATIONS—XJ VEHICLES 8W - 95 - 5 Fig. 5 Engine Splices 2.5L XJ Fig. 6 Instrument Panel Splices XJ...
Page 826 8W - 95 - 6 8W-95 SPLICE LOCATIONS—XJ VEHICLES...
Page 827 8W-95 SPLICE LOCATIONS—XJ VEHICLES 8W - 95 - 7 Fig. 8 Body Splices XJ Fig. 9 Cross-body Splices XJ...
Page 828 8W - 95 - 8 8W-95 SPLICE LOCATIONS—XJ VEHICLES Fig. 10 Body Splices XJ Fig. 11 Roof Splices XJ...
Page 829 8W-95 SPLICE LOCATIONS—XJ VEHICLES 8W - 95 - 9 Fig. 12 Door Splices XJ Fig. 13 Liftgate Splices XJ...
Page 830 8W - 95 - 10 8W-95 SPLICE LOCATIONS—XJ VEHICLES Fig. 14 Trailer Tow Splices XJ...
Page 831 WIRING DIAGRAMS—XJ-RHD 8W - 1 - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION—WIRING 8W-48 HEATED REAR WINDOW ..8W-48-1 DIAGRAMS ..... . 8W-01-1 8W-49 OVERHEAD CONSOLE .
Page 833 8W-10 FUSE/FUSE BLOCK—XJ-RHD 8W - 10 - 1 FUSE/FUSE BLOCK GENERAL INFORMATION DIAGRAM INDEX This section covers the Fuse Block and all circuits Component Page involved with it. For additional information on sys- tem operation, refer to the appropriate section of the ABS Control Module .
Page 845 8W-11 POWER DISTRIBUTION—XJ-RHD 8W - 11 - 1 POWER DISTRIBUTION GENERAL INFORMATION This section covers the Power Distribution Center (PDC) and all circuits involved with it. For additional information on system operation, refer to the appro- priate section of the wiring diagrams. DIAGRAM INDEX Component Page...
Page 863 8W-15 GROUND DISTRIBUTION—XJ-RHD 8W - 15 - 1 GROUND DISTRIBUTION GENERAL INFORMATION DIAGRAM INDEX This section identifies the vehicle grounds, splices Component Page connected to each ground, and the components con- nected to each ground. Refer to the appropriate sec- G101 .
Page 869 8W-20 CHARGING SYSTEM—XJ-RHD 8W - 20 - 1 CHARGING SYSTEM CHARGING SYSTEM When the engine operates and there is current in the generator field, the generator produces a B+ volt- The charging system is an integral part of the bat- age.
Page 871 8W-21 STARTING SYSTEM—XJ-RHD 8W - 21 - 1 STARTING SYSTEM STARTING SYSTEM HELPFUL INFORMATION • The Park/Neutral switch closes when the trans- Circuit A0 from the battery is double crimped at the positive battery post. One branch of circuit A0 mission is in either the PARK or NEUTRAL posi- (battery positive cable) connects to the engine starter tions.
Page 873 8W-30 FUEL/IGNITION—XJ-RHD 8W - 30 - 1 FUEL/IGNITION INDEX page page Automatic Shut Down (ASD) Relay ... . . 1 Idle Air Control (IAC) Motor ....2 Battery Feed .
Page 874 8W - 30 - 2 8W-30 FUEL/IGNITION—XJ-RHD • Circuit A141 also supplies battery voltage to the cuit A142 supplies voltage to the fuel injectors. Each injector has a separate ground circuit controlled by heated oxygen sensor. the PCM. FUEL PUMP MODULE Circuit K11 provides ground for injector number one.
Page 875 8W-30 FUEL/IGNITION—XJ-RHD 8W - 30 - 3 • Crankshaft position sensor HELPFUL INFORMATION • Circuit G7 splices to the speedometer. • Intake air temperature sensor • Circuit K7 splices to supply 8 volts to the camshaft • Throttle position sensor •...
Page 876 8W - 30 - 4 8W-30 FUEL/IGNITION—XJ-RHD THROTTLE POSITION SENSOR From circuit K21, the intake air temperature sen- sor draws voltage from the PCM. The sensor is a From the Powertrain Control Module (PCM), cir- variable resistor. As intake air temperature changes, cuit K6 supplies 5 volts to the throttle position sen- the resistance in the sensor changes, causing a sor (TPS).
Page 877 8W-30 FUEL/IGNITION—XJ-RHD 8W - 30 - 5 DIAGRAM INDEX HELPFUL INFORMATION • If the system loses ground for the Z11 circuits at the right rear of the engine, the vehicle will not op- Component Page erate. Check the connection at the ganged-ground cir- Automatic Shut Down Relay .
Page 885 8W-31 TRANSMISSION CONTROLS—XJ-RHD 8W - 31 - 1 TRANSMISSION CONTROLS FOUR-WHEEL DRIVE (4WD) SWITCH The TCM powers the S1 solenoid on circuit 510, the S2 solenoid on circuit 509, and the S3 solenoid on When the 4WD switch closes, circuit Z1 provides circuit 508.
Page 889 8W-32 ANTI-LOCK BRAKES—XJ-RHD 8W - 32 - 1 ANTI-LOCK BRAKES INDEX page page ABS Power Relay ......1 Data Link Connector .
Page 890 8W - 32 - 2 8W-32 ANTI-LOCK BRAKES—XJ-RHD ABS pump motor relay. The ABS control module pro- For the right front dump solenoid, the ABS module vides ground for the relay on circuit B116. Circuit provides a ground path on circuit B248. Circuit B248 B116 connects to cavity 15 of the ABS control mod- connects to cavity 21 of the ABS control module.
Page 891 8W-32 ANTI-LOCK BRAKES—XJ-RHD 8W - 32 - 3 DIAGRAM INDEX Component Page ABS Control Module ....8W-32-4 thru 8 ABS Hydraulic Unit ..... . .8W-32-6 ABS Power Relay .
Page 897 8W-33 VEHICLE SPEED CONTROL—XJ-RHD 8W - 33 - 1 VEHICLE SPEED CONTROL VEHICLE SPEED CONTROL Circuit V31 provides the SET/COAST signal to cav- ity 48 of the PCM. Circuit V33 sends the RESUME/ The vehicle speed control system is operated by the ACCEL signal to cavity 50 of the PCM.
Page 901 8W-40 INSTRUMENT CLUSTER—XJ-RHD 8W - 40 - 1 INSTRUMENT CLUSTER INDEX page page ABS Warning Lamp ......2 Instrument Cluster .
Page 902 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER—XJ-RHD LOW WASHER FLUID WARNING LAMP TURN SIGNAL INDICATOR LAMPS Circuit G29 connects the low washer fluid switch to Circuits L61 and L60 power for the turn signal in- the warning lamp in the instrument cluster. Circuit dicator lamps.
Page 903 8W-40 INSTRUMENT CLUSTER—XJ-RHD 8W - 40 - 3 DIAGRAM INDEX Component Page Component Page 4WD Switch ......8W-40-9, 13 Fuse 26 (Fuse Block) .
Page 915 8W-41 HORN/CIGAR LIGHTER—XJ-RHD 8W - 41 - 1 HORN/CIGAR LIGHTER HORN CIGAR LIGHTER In the ACCESSORY or RUN position, the ignition The horn system uses two switches and horn relay. switch supplies voltage to fuse 13 in the fuse block The horn switches are on the steering wheel.
Page 919 8W-42 AIR CONDITIONING/HEATER—XJ-RHD 8W - 42 - 1 AIR CONDITIONING/HEATER CONTENTS page page A/C-HEATER SYSTEM ..... . 1 HEATER SYSTEM ......1 GENERAL INFORMATION referring to the circuit descriptions or wiring dia- grams, ensure that you use the correct sub-section.
Page 920 8W - 42 - 2 8W-42 AIR CONDITIONING/HEATER—XJ-RHD fuse 4 in the fuse block. Fuse 4 supplies power to the When the PCM grounds the coil side of the radia- A/C-Heater control switch on circuit C7. tor fan relay, the contacts close and connect circuit Circuit C43 from the A/C-heater switch splices to F141 from fuse 15 in the PDC to circuit C25.
Page 925 8W-44 INTERIOR LIGHTING—XJ-RHD 8W - 44 - 1 INTERIOR LIGHTING INDEX page page Cargo Lamp and Dome Lamp ....1 Ignition Switch Lamp ......1 Chime/Buzzer Module .
Page 926 8W - 44 - 2 8W-44 INTERIOR LIGHTING—XJ-RHD CHIME/BUZZER MODULE Circuit G10 from the buzzer connects to the seat belt switch. When the seat belt switch closes a path The buzzer or optional chime module sounds an au- to ground is completed on circuit Z1 and the tone dible warning tone.
Page 935 8W-47 AUDIO SYSTEM—XJ-RHD 8W - 47 - 1 RADIO • Circuit A3 from fuse 5 in the PDC supplies power RADIO to the fuse block for fuse 9. Fuse 9 protects circuit When the ignition switch is in the ACCESSORY or L7.
Page 943 8W-48 HEATED REAR WINDOW—XJ-RHD 8W - 48 - 1 HEATED REAR WINDOW HEATED REAR WINDOW HELPFUL INFORMATION • When the ignition switch is in the ACCESSORY or The heated rear window relay supplies power to RUN positions, it connects circuit A1 from fuse 11 in heated rear window grid.
Page 947 8W-49 OVERHEAD CONSOLE—XJ-RHD 8W - 49 - 1 OVERHEAD CONSOLE OVERHEAD CONSOLE LAMPS Circuit M1 supplies voltage for the case grounded When the ignition switch is in the START or RUN reading lamps in the overhead console. Fuse 16 in position, it connects circuit A1 from fuse 6 in the the Power Distribution Center (PDC) supplies volt- Power Distribution Center (PDC) to circuit A21.
Page 951 8W-50 FRONT LIGHTING—XJ-RHD 8W - 50 - 1 FRONT LIGHTING INDEX page page Diagram Index ......3 Headlamp Relay .
Page 952 8W - 50 - 2 8W-50 FRONT LIGHTING—XJ-RHD energized, the relay supplies power to the dimming FOG LAMPS module on a branch of circuit A38. Circuit Z1 pro- The fog lamps are controlled by the fog lamp vides ground for the dimming relay. switch and fog lamp relay.
Page 953 8W-50 FRONT LIGHTING—XJ-RHD 8W - 50 - 3 DIAGRAM INDEX Component Page Chime/Buzzer Module ..... .8W-50-6 Dimming Module ......8W-50-9 Dimming Relay .
Page 961 8W-51 REAR LIGHTING—XJ-RHD 8W - 51 - 1 REAR LIGHTING TAIL LAMPS AND REAR LICENSE PLATE LAMPS BACK-UP LAMPS In the START or RUN position, the ignition switch Circuit A3 from fuse 5 in the Power Distribution connects circuit A1 from fuse 6 in the Power Distri- Center (PDC) connects to a bus bar in the fuse block bution Center (PDC) to circuit A21.
Page 967 8W-52 TURN SIGNALS—XJ-RHD 8W - 52 - 1 TURN SIGNALS TURN SIGNAL RELAY HAZARD FLASHERS In the RUN position, the ignition switch connects When the operator selects the hazard flashers, the circuit A1 from fuse 6 in the Power Distribution Cen- multi-function switch connects circuit L12 from the ter (PDC) to circuit A21.
Page 971 8W-53 WIPERS—XJ-RHD 8W - 53 - 1 WIPERS INDEX page page Diagram Index ......2 Rear Wiper System .
Page 972 8W - 53 - 2 8W-53 WIPERS—XJ-RHD DIAGRAM INDEX Component Page Front Wiper Motor ..... .8W-53-3, 4 Front Washer Pump Motor ....8W-53-3, 5 Fuse 3 (Fuse Block) .
Page 977 8W-54 TRAILER TOW—XJ-RHD 8W - 54 - 1 TRAILER TOW TRAILER TOW LEFT TURN RELAY The factory installed trailer tow system in this ve- Power for the coil side of the left turn relay is sup- hicle uses three relays and a circuit breaker along plied by circuit L61.
Page 981 8W-60 POWER WINDOWS—XJ-RHD 8W - 60 - 1 POWER WINDOWS INDEX page page Diagram Index ......2 Power Windows .
Page 982 8W - 60 - 2 8W-60 POWER WINDOWS—XJ-RHD Ground for the window motor is supplied on the For window UP operation, the circuits are reversed. Q12 circuit back to the right rear door switch. Circu- Circuit Q12 is the power and circuits Q22 and Q18 ity internal to the switch then passes the ground to are the ground.
Page 985 8W-61 POWER DOOR LOCKS—XJ-RHD 8W - 61 - 1 POWER DOOR LOCKS POWER DOOR LOCKS UNLOCK RELAY Circuit A7 from fuse 3 in the Power Distribution Two relays provide power for the power door lock Center (PDC) powers circuits P37 and P38 through motors.
Page 989 8W-62 POWER MIRRORS—XJ-RHD 8W - 62 - 1 POWER MIRRORS INDEX page page Diagram Index ......1 Power Mirrors .
Page 993 8W-63 POWER SEAT—XJ-RHD 8W - 63 - 1 POWER SEAT POWER SEAT When the operator selects the REAR VERTICAL UP function, power is passed on the A11 circuit Battery voltage for the power seat system is sup- through the closed contacts in the switch to the S1 plied by circuit A11 from fuse 1 in the fuse block.
Page 995 8W-70 SPLICE INFORMATION—XJ-RHD 8W - 70 - 1 SPLICE INFORMATION GENERAL INFORMATION the systems they affect are referenced. For viewing the location of each splice in the vehicle, refer to Sec- This section identifies all splices in the wiring dia- tion 8W-95.
Page 1025 8W-80 CONNECTOR PIN OUTS—XJ-RHD 8W - 80 - 1 CONNECTOR PIN OUTS GENERAL INFORMATION circuit occupies. Individual connector numbers are referenced on diagram pages throughout Group 8W. The pages referenced in this section show the con- nector, the circuits in the connector, and the pin that CONNECTOR LOCATIONS Component Page...
Page 1026 8W - 80 - 2 8W-80 CONNECTOR PIN OUTS—XJ-RHD Component Page Component Page C237 ....... .8W-80-31 C338 .
Page 1081 8W-90 CONNECTOR LOCATIONS—XJ-RHD 8W - 90 - 1 CONNECTOR LOCATIONS GENERAL INFORMATION nector index is provided. Use the wiring diagrams in each section for connector number identification. Re- This section provides illustrations identifying com- fer to the index for the proper figure number. ponent and connector locations in the vehicle.
Page 1082 8W - 90 - 2 8W-90 CONNECTOR LOCATIONS—XJ-RHD Connector # Color Location Fig. Connector # Color Location Fig. C239 ..BK . . . Rear of A/C-Heater Controls ..10 C345 ..BK . . . Below Left Rear Seat ..14 C240 .
Page 1083 Fig. 1 Front End Lighting Connectors...
Page 1084 Fig. 2 Engine Compartment Wiring Connectors—Right Side...
Page 1085 Fig. 3 Engine Compartment Wiring Connectors—Left Side...
Page 1086 Fig. 4 Engine Wiring Connectors...
Page 1087 8W-90 CONNECTOR LOCATIONS—XJ-RHD 8W - 90 - 7 Fig. 5 Battery and Generator Wiring Fig. 6 Steering Column Wiring Connectors...
Page 1088 8W - 90 - 8 8W-90 CONNECTOR LOCATIONS—XJ-RHD...
Page 1089 Fig. 8 Fuse Block and Relay Center...
Page 1090 8W - 90 - 10 8W-90 CONNECTOR LOCATIONS—XJ-RHD...
Page 1091 Fig. 10 Instrument Cluster Connectors...
Page 1092 8W - 90 - 12 8W-90 CONNECTOR LOCATIONS—XJ-RHD...
Page 1093 Fig. 12 Front Door Wiring Connectors...
Page 1094 Fig. 13 Rear Door Wiring Connectors...
Page 1095 8W-90 CONNECTOR LOCATIONS—XJ-RHD 8W - 90 - 15 Fig. 14 ABS Wheel Speed Sensor Connectors Fig. 15 Rear Wiring Connectors...
Page 1096 8W - 90 - 16 8W-90 CONNECTOR LOCATIONS—XJ-RHD Fig. 16 Trailer Tow Wiring Connector Fig. 17 Center High Mounted Stop Lamps...
Page 1097 Fig. 18 Liftgate Wiring Connectors...
Page 1098 8W - 90 - 18 8W-90 CONNECTOR LOCATIONS—XJ-RHD Fig. 19 Floor Console Wiring Connectors Fig. 20 Transmission Wiring Connectors...
Page 1099 8W-95 SPLICE LOCATIONS—XJ-RHD 8W - 95 - 1 SPLICE LOCATIONS GENERAL INFORMATION index is provided. Use the wiring diagrams in each section for splice number identification. Refer to the This section provides illustrations identifying the index for the proper splice number. general location of the splices in this vehicle.
Page 1100 8W - 95 - 2 8W-95 SPLICE LOCATIONS—XJ-RHD Splice Splice Locations Fig. Locations Fig. Number Number S305 ..In T/O for Fuel Tank Module ... .9 S313 .
Page 1101 8W-95 SPLICE LOCATIONS—XJ-RHD 8W - 95 - 3 Fig. 1 Front End Lighting Splices XJ-RHD Fig. 2 Engine Compartment Splices, Left Side XJ-RHD...
Page 1102 8W - 95 - 4 8W-95 SPLICE LOCATIONS—XJ-RHD Fig. 3 Engine Compartment Splices, Right Side XJ-RHD Fig. 4 Engine Splices XJ-RHD...
Page 1103 8W-95 SPLICE LOCATIONS—XJ-RHD 8W - 95 - 5 Fig. 5 ABS Control Module XJ-RHD...
Page 1104 Fig. 6 Instrument Panel Splices XJ-RHD...
Page 1105 8W-95 SPLICE LOCATIONS—XJ-RHD 8W - 95 - 7 Fig. 7 Crossbody Harness Splices XJ-RHD Fig. 8 Right Front Door XJ-RHD...
Page 1106 8W - 95 - 8 8W-95 SPLICE LOCATIONS—XJ-RHD Fig. 9 Left Body Harness and Right Rear Door Splices XJ-RHD Fig. 10 Overhead Console XJ-RHD...
Page 1107 8W-95 SPLICE LOCATIONS—XJ-RHD 8W - 95 - 9 Fig. 11 Trailer Tow Splices XJ-RHD Fig. 12 Liftgate Splices XJ-RHD...
Page 1109 ENGINES 9 - 1 ENGINES CONTENTS page page LUBRICATION SYSTEM ....37 4.0L ENGINE SERVICE PROCEDURES ..55 LUBRICATION SYSTEM .
Page 1110 9 - 2 ENGINES minutes). The use of a locating dowel is recom- (j) If cylinder(s) have abnormally low compres- mended during assembly to prevent smearing the sion pressures, repeat steps 4a through 4h. material off location. (k) If the same cylinder(s) repeat an abnormally Mopar Gasket Maker should be applied sparingly low reading, it could indicate the existence of a to one gasket surface.
Page 1111 ENGINES 9 - 3 • ALL ENGINES—When checking No.1 main bear- CAUTION: DO NOT use engine or transmission oil, mineral spirits or kerosene. ing; shim No.2 main bearing. • ALL ENGINES—When checking No.2 main bear- (3) Honing should be done by moving the hone up ing;...
Page 1112 9 - 4 ENGINES Heli-Coil tools and inserts are readily available from automotive parts jobbers. SERVICE ENGINE ASSEMBLY (SHORT BLOCK) A service replacement engine assembly (short block) may be installed whenever the original cylin- der block is defective or damaged beyond repair. It consists of the cylinder block, crankshaft, piston and rod assemblies.
Page 1113 ENGINES 9 - 5 ENGINE DIAGNOSIS Engine diagnosis is helpful in determining the (5) Insert a compression pressure gauge and rotate causes of malfunctions not detected and remedied by the engine with the engine starter motor for three routine tune-ups. revolutions.
Page 1114 9 - 6 ENGINES CYLINDER COMBUSTION PRESSURE LEAKAGE (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area TEST of oil leak. If the oil leak is found and identified, re- The combustion pressure leakage test provides an pair per service manual instructions.
Page 1115 ENGINES 9 - 7 filter runoff, and main bearing cap to cylinder (6) For bubbles that remain steady with shaft ro- tation, no further inspection can be done until disas- block mating surfaces. See Group 9, Engines for sembled. Refer to the service Diagnosis—Mechanical, proper repair procedures of these items.
Page 1116 9 - 8 ENGINES SERVICE DIAGNOSIS—PERFORMANCE...
Page 1117 ENGINES 9 - 9 SERVICE DIAGNOSIS—PERFORMANCE...
Page 1118 9 - 10 ENGINES SERVICE DIAGNOSIS—PERFORMANCE—CONT.
Page 1119 ENGINES 9 - 11 SERVICE DIAGNOSIS—MECHANICAL...
Page 1120 9 - 12 ENGINES SERVICE DIAGNOSIS—LUBRICATION...
Page 1121 2.5L ENGINE 9 - 13 2.5L ENGINE SERVICE PROCEDURES INDEX page page Camshaft ....... 32 Oil Pan .
Page 1122 9 - 14 2.5L ENGINE The digits of the code identify: (1) 1st Digit—The year (4 = 1994). (2) 2nd & 3rd Digits—The month (01 - 12). (3) 4th & 5th Digits—The engine type/fuel system/ compression ratio (HX = A 2.5 liter (150 CID) 9.1:1 compression ratio engine with a multi-point fuel in- jection system).
Page 1123 2.5L ENGINE 9 - 15 Fig. 8 Support Cushion Bracket—Left Side (3) Support the engine. (4) Remove through bolt nut (Fig. 9). DO NOT re- move the through bolt. (5) Remove the retaining bolts and nuts from the support cushions (Fig. 9). (6) Remove the through bolt.
Page 1124 9 - 16 2.5L ENGINE (b) If necessary on 2WD vehicles, remove the INSTALLATION—YJ VEHICLES (1) If the engine support bracket was removed, po- bolts holding the transmission support adaptor sition the bracket onto the block and install the at- bracket to the transmission (Fig.
Page 1125 2.5L ENGINE 9 - 17 (5) Remove the transmission support. (6) Lower the vehicle. (7) Connect negative cable to battery. REMOVAL—YJ VEHICLES (1) Disconnect negative cable from battery. (2) Raise the vehicle and support the transmission. (3) Remove the nuts holding the support cushion to the skid plate (Figs.
Page 1126 9 - 18 2.5L ENGINE (3) Remove the radiator drain cock and radiator cap to drain the coolant. DO NOT waste usable cool- ant. If the solution is clean, drain the coolant into a clean container for reuse. (4) Remove the lower radiator hose. (5) Remove the upper radiator hose and coolant re- covery hose (Fig.
Page 1127 2.5L ENGINE 9 - 19 Fig. 16 Heater Hoses (LH Drive Vehicles), Throttle Linkage & Quick-Connect Fuel Lines Fig. 18 Air Cleaner and Power Steering Pump (29) Remove the upper flywheel and converter housing bolts and loosen the bottom bolts. (30) Remove the engine support cushion-to-engine compartment bracket bolts.
Page 1128 9 - 20 2.5L ENGINE (a) Align the transmission torque converter hous- (29) Fill the power steering reservoir. ing with the engine. (30) Connect the battery cables. (b) Loosely install the converter housing lower (31) Install the hood. bolts and install the next higher bolt and nut on (32) Install the air cleaner.
Page 1129 2.5L ENGINE 9 - 21 (7) Disconnect the wires at the starter motor sole- (a) Disconnect the hoses from the fittings at the noid and injection wire harness connector. steering gear. (8) Disconnect the quick-connect fuel lines at the (b) Drain the pump reservoir. (c) Cap the fittings on the hoses and steering fuel rail and return line by squeezing the two retain- gear to prevent foreign objects from entering the...
Page 1130 9 - 22 2.5L ENGINE (14) Install the remaining flywheel housing bolts. ENGINE CYLINDER HEAD COVER Tighten the bolts to 38 N m (28 ft. lbs.) torque. A cured gasket is part of the engine cylinder head (15) Install the starter motor and connect the ca- cover.
Page 1131 2.5L ENGINE 9 - 23 (3) Connect the CCV hoses (Fig. 1). Inspect each push rod end for excessive wear and (4) Connect negative cable to battery. replace as required. If any push rod is excessively worn because of lack of oil, replace it and inspect the VALVE COMPONENT REPLACE—CYLINDER HEAD corresponding hydraulic tappet for excessive wear.
Page 1132 9 - 24 2.5L ENGINE Compressor Tool MD-998772A to compress the spring (7) Install the rocker arms, pivots and bridge at and remove the locks (Fig. 7). their original location. (9) Remove valve spring and retainer (Fig. 7). (8) Tighten the bridge capscrews alternately, one (10) Remove valve stem oil seals (Fig.
Page 1133 2.5L ENGINE 9 - 25 (1) Dip each tappet in Mopar Engine Oil Supple- LEAK-DOWN TEST After cleaning and inspection, test each tappet for ment, or equivalent. specified leak-down rate tolerance to ensure zero-lash (2) Use Hydraulic Valve Tappet Removal/Installa- operation (Fig.
Page 1134 9 - 26 2.5L ENGINE (9) If equipped, disconnect the power steering INSTALLATION pump bracket. Set the pump and bracket aside. DO The engine cylinder head gasket is a composition NOT disconnect the hoses. gasket. The gasket is to be installed DRY. DO NOT (10) Remove the fuel lines and vacuum advance use a gasket sealing compound on the gasket.
Page 1135 2.5L ENGINE 9 - 27 (15) Install the fuel lines and the vacuum advance CAUTION: Engine cylinder head bolts should be re- used only once. Replace the head bolts if they were hose. used before or if they have a paint dab on the top (16) If equipped, attach the power steering pump of the bolt.
Page 1136 9 - 28 2.5L ENGINE (2) Use Valve Spring Compressor Tool VALVE SEAT REFACING MD-998772A and compress each valve spring. (1) Install a pilot of the correct size in the valve (3) Remove the valve locks, retainers, springs and guide bore. Reface the valve seat to the specified an- valve stem oil seals.
Page 1137 2.5L ENGINE 9 - 29 PREFERRED METHOD: (1) Remove the valve from the head. (2) Clean the valve stem guide bore with solvent and a bristle brush. (3) Insert a telescoping gauge into the valve stem guide bore approximately 9.525 mm (.375 inch) from the valve spring side of the head (Fig.
Page 1138 9 - 30 2.5L ENGINE at the engine cylinder head. Also tap the top of the retainer to seat the valve locks. (8) Install the engine cylinder head. VALVE TIMING Disconnect the spark plug wires and remove the spark plugs. Remove the engine cylinder head cover.
Page 1139 2.5L ENGINE 9 - 31 oil on the vibration damper hub contact surface of area while installing the seal. Force it into position the seal. with Seal Installation Tool 6139. (9) Apply Mopar Silicone Rubber Adhesive Sealant (2) Position the gasket on the cylinder block. to the keyway in the crankshaft and insert the key.
Page 1140 9 - 32 2.5L ENGINE (2) Pull the tensioner block toward the ten- REMOVAL (1) Disconnect negative cable from battery. sioner lever to compress the spring. Hold the (2) Remove the fan and shroud. block and turn the tensioner lever to the lock (3) Remove the serpentine drive belt.
Page 1141 2.5L ENGINE 9 - 33 Fig. 10 Camshaft INSTALLATION (1) Lubricate the camshaft with Mopar Engine Oil Supplement, or equivalent. (2) Carefully install the camshaft to prevent dam- age to the camshaft bearings (Fig. 10). (3) Turn the tensioner lever to the unlocked (down) Fig.
Page 1142 9 - 34 2.5L ENGINE tor in the Component Removal/Installation section of Group 8D, Ignition Systems. (14) Install the distributor and ignition wires. Re- fer to Distributor in the Component Removal/Instal- lation section of Group 8D, Ignition Systems. (15) Install the radiator or radiator and condenser, if equipped with A/C.
Page 1143 2.5L ENGINE 9 - 35 bearing (smallest). This permits easier removal and ant, or equivalent to the joint formed at the timing installation of the camshaft. The camshaft bearings case cover and cylinder block. are pressure lubricated. (10) Position the timing case cover on the oil pan It is not advisable to attempt to replace cam- gasket and the cylinder block.
Page 1144 9 - 36 2.5L ENGINE OIL PAN REMOVAL (1) Disconnect negative cable from battery. (2) Raise the vehicle. (3) Remove the oil pan drain plug and drain the engine oil. (4) Disconnect the exhaust pipe at the engine ex- haust manifold. (5) Disconnect the exhaust hanger at the catalytic converter and lower the pipe.
Page 1145 2.5L ENGINE 9 - 37 LUBRICATION SYSTEM A gear—type positive displacement pump passes through the squirt hole and is thrown off as mounted at the underside of the block opposite the the rod rotates. This oil throwoff lubricates the cam- No.
Page 1146 9 - 38 2.5L ENGINE Fig. 4 Oil Lubrication System...
Page 1147 2.5L ENGINE 9 - 39 OIL PUMP OIL PUMP PRESSURE The MINIMUM oil pump pressure is 89.6 kPa (13 The positive-displacement gear-type oil pump is psi) at 600 rpm. The MAXIMUM oil pump pressure driven by the distributor shaft, which is driven by a is 255-517 kPa (37-75 psi) at 1600 rpm or more.
Page 1148 9 - 40 2.5L ENGINE Fig. 4 Locking Tab Inspection Fig. 2 Removal of Connecting Rod and Piston Assembly ings for normal wear patterns, scoring, grooving, fa- tigue and pitting (Fig. 5). Replace any bearing that shows abnormal wear. Fig. 5 Scoring Caused by Insufficient Lubrication or by Damaged Crankshaft Pin Journal Inspect the connecting rod journals for signs of scoring, nicks and burrs.
Page 1149 2.5L ENGINE 9 - 41 (5) Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plas- tigage across full width of the lower insert at the cen- ter of bearing cap. Plastigage must not crumble in use.
Page 1150 9 - 42 2.5L ENGINE SIDE CLEARANCE MEASUREMENT .0001 increments is required. Piston installation into the cylinder bore requires Slide snug-fitting feeler gauge between the connect- slightly more pressure than that required for non- ing rod and crankshaft journal flange. Refer to En- coated pistons.
Page 1151 2.5L ENGINE 9 - 43 Fig. 13 Top Compression Ring Identification Fig. 11 Ring Side Clearance Measurement Fig. 14 Second Compression Ring Identification Fig. 12 Ring Gap Measurement (5) Install the oil control rings according to instruc- Fig. 15 Compression Ring Chamfer Location tions in the package.
Page 1152 9 - 44 2.5L ENGINE (9) The top compression ring (the scraping edge is Short pieces of rubber hose slipped over the con- gray in color) has a chamfer on the TOP of the inside necting rod bolts will provide protection during in- edge (Fig.
Page 1153 2.5L ENGINE 9 - 45 the insert approximately 25 mm (1 inch), it can be CAUTION: Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pis- removed by applying pressure under the tab. (8) Using the same procedure described above, re- tons face the front of the engine.
Page 1154 9 - 46 2.5L ENGINE DO NOT rotate the crankshaft. This will FITTING (CRANKSHAFT INSTALLED) The main bearing caps, numbered (front to rear) cause the Plastigage to shift, resulting in an in- from 1 through 5 have an arrow to indicate the for- accurate reading.
Page 1155 2.5L ENGINE 9 - 47 FOR EXAMPLE: DO NOT use a standard size up- per insert and a 0.051 mm (0.002 inch) undersize lower insert. If the clearance exceeds specification using a pair of 0.051 mm (0.002 inch) undersize bearing inserts, measure crankshaft journal diameter with a mi- crometer.
Page 1156 9 - 48 2.5L ENGINE MAIN BEARING FITTING CHART...
Page 1157 2.5L ENGINE 9 - 49 (2) Carefully position the seal into place. Use rear main Seal Installer Tool 6271 to install the seal flush with the cylinder block. CAUTION: The felt lip must be located inside the flywheel mounting surface. If the lip is not posi- tioned correctly the flywheel could tear the seal.
Page 1158 9 - 50 2.5L ENGINE INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. Fig. 9 Oil Filter Adaptor Hole Fig. 12 Cylinder Bore Measurement (2) Measure the inside diameter of the cylinder bore at three levels below top of bore.
Page 1159 2.5L ENGINE 9 - 51 (11) Install the oil pan gasket and oil pan. ASSEMBLY Refer to the applicable sections for detailed instruc- (12) Install the vibration damper. tions. (13) Install the water pump. Tighten the mounting (1) Install the crankshaft. bolts to 31 N m (270 in.
Page 1160 9 - 52 2.5L ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS...
Page 1161 2.5L ENGINE 9 - 53 ENGINE SPECIFICATIONS (CONT.)
Page 1162 9 - 54 2.5L ENGINE ENGINE SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS...
Page 1163 4.0L ENGINE 9 - 55 4.0L ENGINE SERVICE PROCEDURES INDEX page page Camshaft ....... 74 Rocker Arms and Push Rods .
Page 1164 9 - 56 4.0L ENGINE The digits of the code identify: (1) 1st Digit—The year (4 = 1994). (2) 2nd & 3rd Digits—The month (01 - 12). (3) 4th & 5th Digits—The engine type/fuel system/ compression ratio (MX = A 4.0 Liter (242 CID) 8.7:1 compression ratio engine with a multi-point fuel in- jection system).
Page 1165 4.0L ENGINE 9 - 57 Fig. 8 Support Cushion Bracket—XJ Vehicles Fig. 6 Front Mounts—XJ Vehicles (5) Remove the engine support. (6) Lower the vehicle. (7) Connect negative cable to battery. ENGINE MOUNT—REAR A resilient rubber cushion supports the transmis- sion at the rear between the transmission extension housing and the rear support crossmember or skid plate.
Page 1166 9 - 58 4.0L ENGINE Fig. 9 Rear Mount—XJ Vehicles (Manual Transmission) (b) On 2WD vehicles, remove the bolts holding the transmission support adaptor bracket to the transmis- sion (Fig. 10). Remove the adaptor bracket. Fig. 10 Rear Mount—XJ Vehicles (Automatic INSTALLATION—XJ VEHICLES Transmission) (1) MANUAL TRANSMISSION:...
Page 1167 4.0L ENGINE 9 - 59 Fig. 12 Rear Mount—YJ Vehicles (Automatic Fig. 11 Rear Mount—YJ Vehicles (Manual Transmission) Transmission) (3) Install the skid plate bolts to the sill and INSTALLATION—YJ VEHICLES tighten to 88 N m (65 ft. lbs.) torque. (1) MANUAL TRANSMISSION: (4) Remove the transmission support.
Page 1168 9 - 60 4.0L ENGINE (16) Disconnect the line pressure cable (if equipped with automatic transmission). (17) Disconnect injection system wire harness con- nector at the dash panel. (18) Disconnect the distributor electrical connec- tion and the oil pressure switch connector. (19) Perform the Fuel System Pressure Release procedure (refer to Group 14, Fuel System).
Page 1169 4.0L ENGINE 9 - 61 (c) Install and tighten the flywheel housing lower bolts finger tight. (3) Vehicles with Automatic Transmission: (a) Align the transmission torque converter hous- ing with the engine. (b) Loosely install the converter housing lower bolts and install the next higher bolt and nut on each side.
Page 1170 9 - 62 4.0L ENGINE (26) Connect the speed control cable, if equipped. (27) Connect the throttle cable linkages. (28) Connect the heater hoses at the engine ther- mostat housing and water pump. (29) Install the fan assembly to the idler pulley. (30) Install the radiator or radiator and condenser (if equipped with A/C).
Page 1171 4.0L ENGINE 9 - 63 Fig. 19 Upper Radiator Hose, Coolant Recovery Fig. 18 Fuel Line Quick-Connect Couplings, Air Hose, Fan Shroud & Power Steering Pump Cleaner Assembly, Throttle & Speed Control Cables (37) Raise the engine off the front supports. (18) Disconnect the oxygen sensor wire connector.
Page 1172 9 - 64 4.0L ENGINE (16) Remove pulley-to-water pump flange (3) Disconnect the fresh air inlet hose from the en- alignment capscrew and install the fan and spacer or gine cylinder head cover (Fig. 1). Tempatrol fan assembly. (4) Remove the engine cylinder head cover mount- (17) Tighten the serpentine drive belt according to ing bolts.
Page 1173 4.0L ENGINE 9 - 65 VALVE COMPONENT REPLACE—CYLINDER HEAD worn because of lack of oil, replace it and inspect the corresponding hydraulic tappet for excessive wear. NOT REMOVED Inspect the push rods for straightness by rolling them on a flat surface or by shining a light between ROCKER ARMS AND PUSH RODS the push rod and the flat surface.
Page 1174 9 - 66 4.0L ENGINE (9) Remove valve stem oil seals (Fig. 3). Note the (8) Tighten the bridge capscrews alternately, one valve seals are different for intake and exhaust at a time, to avoid damaging the bridge. Tighten the valves.
Page 1175 4.0L ENGINE 9 - 67 (1) Dip each tappet in Mopar Engine Oil Supple- LEAK-DOWN TEST After cleaning and inspection, test each tappet for ment, or equivalent. specified leak-down rate tolerance to ensure zero-lash (2) Use Hydraulic Valve Tappet Removal/Installa- operation (Fig.
Page 1176 9 - 68 4.0L ENGINE (9) If equipped, disconnect the power steering Remove the carbon deposits from the combustion pump bracket. Set the pump and bracket aside. DO chambers and top of the pistons. NOT disconnect the hoses. INSPECTION (10) Perform the Fuel System Pressure Release Use a straightedge and feeler gauge to check the procedure (refer to Group 14, Fuel System).
Page 1177 4.0L ENGINE 9 - 69 counter bolts which were painted in an earlier ser- (21) Install the temperature sending unit and con- vice operation, replace them. nect the wire connector. (22) Connect the fuel line. (23) Connect negative cable to battery. (24) Connect the upper radiator hose and heater hose at the engine thermostat housing.
Page 1178 9 - 70 4.0L ENGINE (2) After refacing, a margin of at least 0.787 mm VALVE GUIDES (0.031 inch) must remain (Fig. 8). If the margin is The valve guides are an integral part of the engine less than 0.787 mm (0.031 inch), the valve must be cylinder head and are not replaceable.
Page 1179 4.0L ENGINE 9 - 71 ments differ by more than 0.0635 mm (0.0025 in.), ream the guide bore to accommodate an oversize valve stem. (7) Compare the measured valve guide bore diam- eter with specifications (7.95-7.97 mm or 0.313-0.314 inch). If the measurement differs from specification by more than 0.076 mm (0.003 inch), ream the guide bore to accommodate an oversize valve stem.
Page 1180 9 - 72 4.0L ENGINE VIBRATION DAMPER the engine. Make sure the tension spring and thrust pin do not fall out of the preload bolt. REMOVAL (8) Pry the crankshaft oil seal from the front of the (1) Disconnect negative cable from battery. timing case cover (Fig.
Page 1181 4.0L ENGINE 9 - 73 Fig. 3 Timing Case Cover Alignment and Seal Fig. 4 Timing Case Cover Oil Seal Installation Installation Tool 6139 (11) Install the radiator shroud. (10) Install the A/C compressor (if equipped) and (12) Connect negative cable to battery. generator bracket assembly.
Page 1182 9 - 74 4.0L ENGINE Fig. 6 Camshaft Sprocket Preload Bolt properly aligned ensures correct valve timing. A worn or stretched timing chain will adversely affect valve timing. If the timing chain deflects more than 12.7 mm (1/2 inch) replace it. The correct timing chain has 48 pins.
Page 1183 4.0L ENGINE 9 - 75 Fig. 8 Camshaft Fig. 9 Timing Case Cover Components INSPECTION (14) Install the distributor and ignition wires. Re- Inspect the cam lobes for wear. fer to Distributor in the Component Removal/Instal- Inspect the bearing journals for uneven wear pat- lation section of Group 8D, Ignition Systems.
Page 1184 9 - 76 4.0L ENGINE (3) Remove the fan and shroud. (17) If the pin is a dowel-type pin, center-punch it. (4) Disconnect the radiator overflow tube, radiator Ensure the exact center is located when center- hoses, automatic transmission fluid cooler pipes (if punching the pin.
Page 1185 4.0L ENGINE 9 - 77 (16) Install the vibration damper on the crank- shaft. (17) Lubricate and tighten the damper bolt to 108 N m (80 ft. lbs.) torque. (18) If equipped with air conditioning: (a) Install the A/C compressor serpentine drive belt idler pulley.
Page 1186 9 - 78 4.0L ENGINE Fig. 3 Position of 5/16 inch Oil Pan Bolts Fig. 1 Fabrication of Alignment Dowels (7) Lower the engine until it is properly located on the engine mounts. (8) Install the through bolts and tighten the nuts. (9) Lower the jack stand and remove the piece of wood.
Page 1187 4.0L ENGINE 9 - 79 LUBRICATION SYSTEM A gear—type positive displacement pump passes through the squirt hole and is thrown off as mounted at the underside of the block opposite the the rod rotates. This oil throwoff lubricates the cam- No.
Page 1188 9 - 80 4.0L ENGINE Fig. 4 Oil Lubrication System...
Page 1189 4.0L ENGINE 9 - 81 OIL PUMP OIL PUMP PRESSURE The MINIMUM oil pump pressure is 89.6 kPa (13 A gear-type oil pump is mounted at the underside psi) at 600 rpm. The MAXIMUM oil pump pressure of the cylinder block opposite the No.4 main bearing. is 255-517 kPa (37-75 psi) at 1600 rpm or more.
Page 1190 9 - 82 4.0L ENGINE Fig. 4 Locking Tab Inspection Fig. 2 Removal of Connecting Rod and Piston Assembly ings for normal wear patterns, scoring, grooving, fa- tigue and pitting (Fig. 5). Replace any bearing that shows abnormal wear. Fig. 5 Scoring Caused by Insufficient Lubrication or Inspect the connecting rod journals for signs of by Damaged Crankshaft Pin Journal scoring, nicks and burrs.
Page 1191 4.0L ENGINE 9 - 83 (5) Install the lower bearing insert in the bearing cap. The lower insert must be dry. Place strip of Plas- tigage across full width of the lower insert at the cen- ter of bearing cap. Plastigage must not crumble in use.
Page 1192 9 - 84 4.0L ENGINE SIDE CLEARANCE MEASUREMENT piston, a cylinder bore gauge capable of reading .0001 increments is required. Slide snug-fitting feeler gauge between the connect- Piston installation into the cylinder bore requires ing rod and crankshaft journal flange. Refer to En- slightly more pressure than that required for non- gine Specifications for the proper clearance.
Page 1193 4.0L ENGINE 9 - 85 Fig. 13 Top Compression Ring Identification Fig. 11 Ring Side Clearance Measurement Fig. 14 Second Compression Ring Identification Fig. 12 Ring Gap Measurement Fig. 15 Compression Ring Chamfer Location (5) Install the oil control rings according to instruc- edge (Fig.
Page 1194 9 - 86 4.0L ENGINE (10) Using a ring installer, install the top ring with (3) Use a piston ring compressor to install the con- the chamfer facing up (Fig. 16). The dot will be fac- necting rod and piston assemblies through the top of ing up.
Page 1195 4.0L ENGINE 9 - 87 (8) Lower the vehicle. (9) Install the engine cylinder head, push rods, rocker arms, bridges, pivots and engine cylinder head cover. (10) Fill the crankcase with engine oil. CRANKSHAFT MAIN BEARINGS REMOVAL (1) Disconnect negative cable from battery. (2) Remove the spark plugs.
Page 1196 9 - 88 4.0L ENGINE ward position. The upper main bearing inserts are Remove the bearing cap. Determine the amount of grooved to provide oil channels while the lower in- clearance by measuring the width of the compressed serts are smooth. Plastigage with the scale on the Plastigage envelope Each bearing insert pair is selectively fitted to its (Fig.
Page 1197 4.0L ENGINE 9 - 89 If the clearance exceeds specification using a pair (a) Attach a magnetic base dial indicator to the of 0.051 mm (0.002 inch) undersize bearing inserts, cylinder block at either the front or rear of the en- measure crankshaft journal diameter with a mi- gine.
Page 1198 9 - 90 4.0L ENGINE MAIN BEARING FITTING CHART...
Page 1199 4.0L ENGINE 9 - 91 REMOVAL (1) Remove the engine flywheel or converter drive plate. (2) Remove the oil pan. (3) Remove the rear main bearing cap (No.7). (4) Push the upper seal out of the groove. Ensure that the crankshaft and seal groove are not damaged. (5) Remove the lower half of the seal from the bearing cap.
Page 1200 9 - 92 4.0L ENGINE • The front and rear oil galley holes. piston. A slight amount of taper always exists in the • The feed holes for the crankshaft main bearings. cylinder bore after the engine has been in use for a period of time.
Page 1201 4.0L ENGINE 9 - 93 ENGINE SPECIFICATIONS SPECIFICATIONS...
Page 1202 9 - 94 4.0L ENGINE ENGINE SPECIFICATIONS (CONT.)
Page 1203 4.0L ENGINE 9 - 95 ENGINE SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS...
Page 1205 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page page EXHAUST SYSTEM ..... . . 1 SERVICE PROCEDURES .
Page 1206 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD verter. Such conditions can exist when the engine DO NOT allow the engine to operate at fast idle for misfires or otherwise does not operate at peak effi- extended periods (over 5 minutes). This condition ciency.
Page 1207 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3 SERVICE PROCEDURES INDEX page page Catalytic Converter ......4 Intake Manifold—2.5L Engine .
Page 1208 11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD (3) Remove the oxygen sensor from the exhaust INSTALLATION (1) Assemble exhaust pipe to manifold and cata- pipe (Fig. 2). lytic converter loosely to permit proper alignment of (4) Disconnect the exhaust pipe from the engine all parts.
Page 1209 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5 (2) Remove the clamp from the catalytic converter REMOVAL and muffler connection (Fig. 6). (1) Raise and support the vehicle. (2) Remove the front muffler clamp from the cata- lytic converter and muffler connection (Fig. 6). (3) Remove the rear exhaust tailpipe hanger clamp (Fig.
Page 1210 11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD • To remove an original equipment exhaust tailpipe/ muffler combination, cut the exhaust tailpipe close to the muffler. Collapse the part remaining in the muf- fler and remove. • To remove a service exhaust tailpipe/muffler com- bination, apply heat until the metal becomes cherry red.
Page 1211 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7 eign material to enter either the intake mani- INSTALLATION (1) Install the muffler onto the catalytic converter fold or the ports in the cylinder head. outlet. Ensure that the locator on the converter INSTALLATION aligns with the notch on the muffler, if so equipped.
Page 1212 11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD CAUTION: When disconnecting the cruise control INSTALLATION connector at the throttle body, DO NOT pry the con- (1) Install the new intake manifold gasket over the locating dowels. nector off with pliers or screwdriver. Use finger pressure only.
Page 1213 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9 • Fasteners Nos.8 through 11—Tighten to 33 N m (2) Remove air cleaner inlet hose from throttle plate assembly. (24 ft. lbs.) torque. (3) Remove the air cleaner assembly. (4) Remove the throttle cable, cruise control cable (if equipped) and the transmission line pressure ca- ble.
Page 1214 11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD TORQUE SPECIFICATIONS...
Page 1215 • The other (lessor) body damage—secondary dam- GENERAL INFORMATION age. Jeep XJ Vehicles (Fig. 1) and the cab section of • Damage to the exterior trim and other surface-at- Jeep are constructed as a unitized body and frame. tached components.
Page 1217 XJ—FRAME 13 - 3 (2) Attach the skid plate to the frame sill and crossmember with bolts. Tighten bolts to 22 N m (16 ft. lbs.) torque. FUEL TANK SKID PLATE REMOVAL (1) Position a support under skid plate. (2) Remove the bolts that attach skid plate to un- derbody side rails (Fig.
Page 1218 13 - 4 XJ—FRAME FUEL FILLER HOSE SPLASH SHIELD—XJ VEHICLES REMOVAL (1) Remove the screws that attach fuel filler hose splash shield to wheelhouse panel and frame rail (Fig. 7). Fig. 8 Fuel Tank Support Strap—XJ Vehicles Fig. 7 Fuel Filler Hose Splash Shield—XJ Vehicles (2) Remove the hose splash shield from wheel- house panel and frame rail (Fig.
Page 1219 XJ—BUMPERS 13 - 5 BUMPERS INDEX page page Front Bumper ......5 Rear Bumper .
Page 1220 13 - 6 XJ—BUMPERS The retaining screws and the steering gear skid plate must be removed before the left strap can be removed from the sillmember. (5) Detach the tow hook straps from the sillmem- ber. (6) Support the bumper. (7) Remove the bolts that attach the bumper sup- port brackets to the right and left sillmembers (Fig.
Page 1221 XJ—BUMPERS 13 - 7 (12) Remove the fog lamps (Fig. 10) from the (6) Install the license plate bracket on the bumper bumper rail. rail. Tighten the nuts securely. (7) Install the fog lamps on the bumper rail. Tighten the nuts to 20 N m (15 ft. lbs.) torque. (8) If removed, install the vacuum reservoir(s) on the bumper rail.
Page 1222 13 - 8 XJ—BUMPERS (10) Remove the support bracket from the bumper rail. INSTALLATION (1) Install the bumper guard and bumper support bracket on the bumper rail. Tighten the retaining hardware in the sequence indicated in Figure 7. Tighten locknuts to 20 N m (15 ft. lbs.) torque. Tighten bolts to 56 N m (41 ft.
Page 1223 XJ—BUMPERS 13 - 9 REAR TOW HOOK REMOVAL (1) Remove the bolts that attach tow hook bracket to the frame rail and reinforcement bracket (Fig. 16). The reinforcement bracket is held on the Fig. 15 Bumper Guard Removal/Installation—XJ Fig. 16 Rear Tow Hook—XJ Vehicles Vehicles frame rail with two blind rivets.
Page 1224 GENERAL INFORMATION VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY The Jeep YJ (Fig. 1) frame is the structural center CAN RESULT. of the vehicle. In addition to supporting the body and DO NOT ALLOW OPEN FLAME TO CONTACT payload, the frame provides a station for the engine.
Page 1225 Fig. 2 YJ Body & Frame...
Page 1226 13 - 12 YJ—FRAME Fig. 3 Body HoldDowns—YJ Vehicles...
Page 1227 YJ—FRAME 13 - 13 The frame is constructed of high-strength channel steel siderails and crossmembers. The crossmembers join the siderails and retain them in alignment in re- lation to each other. This provides resistance to frame twists and strains. FRAME STRAIGHTENING When necessary, a conventional frame that is bent or twisted can be straightened by application of heat.
Page 1229 YJ—FRAME 13 - 15 (4) Remove the nuts and bolts that attach the skid plate to the frame. (5) Remove the skid plate from the vehicle. INSTALLATION (1) Position the skid plate at the frame and trans- mission support cushion. (2) Attach the skid plate to the frame.
Page 1230 13 - 16 YJ—BUMPERS BUMPERS INDEX page page Frame Crossmember Cover ....16 Rear Bumper ......16 Front Bumper .
Page 1231 YJ—BUMPERS 13 - 17 (2) Remove the bumperettes, spacers, brackets and draw bar from the rear crossmember. INSTALLATION (1) Position the spacers, brackets, draw bar and bumperettes on the rear crossmember. (2) Install the retaining nuts, bolts and washers in the frame rear crossmember.
Page 1233 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page ACCELERATOR PEDAL AND THROTTLE CABLE . 17 OPERATION ......19 FUEL DELIVERY SYSTEM .
Page 1234 14 - 2 FUEL SYSTEM line. You may encounter fuels containing 3 percent or CLEAN AIR GASOLINE more methanol along with other alcohols called cosol- Many gasolines are now being blended that con- vents. tribute to cleaner air, especially in those areas of the Problems that are the result of using methanol/gas- country where air pollution levels are high.
Page 1235 FUEL DELIVERY SYSTEM 14 - 3 FUEL DELIVERY SYSTEM INDEX page page Fuel Filter ....... . 9 Fuel Pump Module .
Page 1236 14 - 4 FUEL DELIVERY SYSTEM (8) Remove fuel pump module and O-ring seal. (2) Install fuel pump module assembly and new O- Discard old O-ring and fuel pump module inlet filter. ring seal. The rubber stopper on the end of the fuel return tube of the assembly must be inserted into the DISASSEMBLY—XJ MODELS cup in the fuel tank reservoir (Fig.
Page 1237 FUEL DELIVERY SYSTEM 14 - 5 (2) Remove fuel filler cap. Perform the Fuel Pres- (4) Remove fuel pump top mounting bracket nut sure Release Procedure as outlined in this group. (Fig. 6). Remove fuel pump. (3) Remove fuel tank. Refer to Fuel Tank Remov- al—YJ Models.
Page 1238 14 - 6 FUEL DELIVERY SYSTEM FUEL PRESSURE RELEASE PROCEDURE idle speed, system fuel pressure should be approxi- mately 214 kPa (31 psi) with the vacuum line con- WARNING: THE FUEL SYSTEM IS UNDER CON- nected to the regulator. With the vacuum line STANT FUEL PRESSURE (EVEN WITH THE ENGINE disconnected from the regulator, fuel pressure should OFF) OF APPROXIMATELY 131-269 KPA (19-39 PSI).
Page 1239 FUEL DELIVERY SYSTEM 14 - 7 OK and fuel pressure does not rise approximately If fuel pump pressure does not rise to approxi- 8-10 psi after disconnecting vacuum line, replace fuel mately 75 psi within two seconds, proceed as follows: pressure regulator.
Page 1240 14 - 8 FUEL DELIVERY SYSTEM FUEL PRESSURE LEAK DOWN TEST (7) Disconnect both fuel lines at fuel rail near fuel pressure regulator. For procedures, refer to Fuel ENGINE OFF Tubes/Lines/Hoses and Clamps. Also refer to Quick- Abnormally long periods of cranking to restart a Connect Fittings.
Page 1241 FUEL DELIVERY SYSTEM 14 - 9 codes are not displayed, the problem may be mechan- REMOVAL ical rather than electronic. WARNING: THE FUEL SYSTEM IS UNDER CON- FUEL FILTER STANT FUEL PRESSURE (EVEN WITH THE ENGINE OFF) OF APPROXIMATELY 131-269 KPA (19-39 PSI). The fuel filter protects the fuel injectors and fuel THIS PRESSURE MUST BE RELEASED BEFORE pressure regulator from dirt, water and other foreign...
Page 1242 14 - 10 FUEL DELIVERY SYSTEM WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRES- SURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE...
Page 1243 FUEL DELIVERY SYSTEM 14 - 11 Fig. 16 Disconnecting Single-Tab Type Fitting Fig. 18 Typical Two-Tab Type Quick-Connect Fitting BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRES- SURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE...
Page 1244 14 - 12 FUEL DELIVERY SYSTEM (7) Insert the quick-connect fitting to the compo- WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH THE ENGINE OFF). nent being serviced and into the plastic retainer. BEFORE SERVICING ANY FUEL SYSTEM HOSES, When a connection is made, a click will be heard.
Page 1245 FUEL TANKS 14 - 13 FUEL TANKS INDEX page page Fuel Gauge Sending Unit ....16 Fuel Tank Pressure Relief/Rollover Valve ..16 Fuel Tank .
Page 1246 14 - 14 FUEL TANKS (2) Remove the fuel filler cap. Using an approved por- table gasoline siphon/storage tank, drain fuel tank. (3) Raise and support vehicle. (4) Disconnect fuel fill hose and fill vent hose from filler neck (Fig. 1). Fig.
Page 1247 FUEL TANKS 14 - 15 (1) Disconnect negative battery cable. (2) Remove the fuel filler cap. Using an approved portable gasoline siphon/storage tank, drain fuel tank. (3) Raise and support vehicle. (4) Using a small straight blade screwdriver, pull back the stems of the push clips that secure the fuel filler neck shroud (located at bottom of left rear wheel well) in place (Fig.
Page 1248 14 - 16 FUEL TANKS (2) Raise skid plate/fuel tank until gauge sender the guide plate at the orifice preventing liquid fuel wire connector can be connected to harness connec- from reaching the EVAP canister. This is done if bot- tor.
Page 1249 ACCELERATOR PEDAL AND THROTTLE CABLE 14 - 17 ACCELERATOR PEDAL AND THROTTLE CABLE GENERAL INFORMATION INSTALLATION (1) Place accelerator pedal assembly over studs The accelerator pedal is connected to the throttle body protruding from floor pan. Tighten mounting nuts to linkage by the throttle cable.
Page 1250 14 - 18 ACCELERATOR PEDAL AND THROTTLE CABLE (2) Snap cable into clip on the engine cylinder pedal arm. Push cable retainer (clip) into pedal arm head (valve) cover. opening until it snaps in place. (3) Push other end of cable through opening in (5) Before starting engine, operate accelerator dash panel until retaining tabs lock into panel.
Page 1251 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 19 MULTI-PORT FUEL INJECTION (MFI)—COMPONENT DESCRIPTION/SYSTEM OPERATION INDEX page page Air Cleaner ......29 Intake Manifold Air Temperature Sensor—...
Page 1252 14 - 20 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION provides a ground for the ignition coil. The coil dis- charges when the PCM supplies a ground. By switch- ing the ground path on and off, the PCM regulates ignition timing. The sensors and switches that provide inputs to the powertrain control module (PCM) comprise the Engine Control System.
Page 1253 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 21 • Signal ground AUTOMATIC SHUTDOWN (ASD) SENSE—PCM Powertrain Control Module (PCM) Outputs: INPUT • A/C clutch relay A 12 volt signal at this input indicates to the PCM • Idle air control (IAC) motor that the ASD has been activated.
Page 1254 14 - 22 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION energized). This is done to compensate for the re- duced flow through injector caused by the lowered voltage. BRAKE SWITCH—PCM INPUT When the brake light switch is activated, the pow- ertrain control module (PCM) receives an input indi- cating that the brakes are being applied.
Page 1255 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 23 Fig. 8 Sensor Location—4.0L Engine Fig. 10 Engine Coolant Temperature Sensor— Typical EXTENDED IDLE SWITCH—PCM INPUT OPTIONAL POLICE PACKAGE ONLY The extended idle switch is used to raise the en- gine idle speed to approximately 1000 rpm. This is when the shifter is in either the Park or Neutral po- sition.
Page 1256 14 - 24 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION The MAP sensor is mounted on the dash panel. speed control operation. Refer to Group 21, Transmis- The sensor is connected to the throttle body with a sions, for testing, replacement and adjustment infor- vacuum hose and to the PCM electrically.
Page 1257 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 25 the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injec- tor pulse width and ignition timing. Fig. 13 Power Steering Pump Pressure Switch—XJ Models SPEED CONTROL—PCM INPUT The speed control system provides three separate...
Page 1258 14 - 26 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION Fig. 18 PDC—XJ Models By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engine operating conditions.
Page 1259 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 27 DATA LINK CONNECTOR—PCM OUTPUT GENERATOR FIELD—PCM OUTPUT Refer to the previous paragraphs on Data Link The powertrain control module (PCM) regulates the Connector—PCM Input for information. charging system voltage within a range of 12.9 to 15.0 volts.
Page 1260 14 - 28 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION The throttle body has an air control passage that provides air for the engine at idle (the throttle plate is closed). The IAC motor pintle protrudes into the air control passage and regulates air flow through it. Based on various sensor inputs, the powertrain con- trol module (PCM) adjusts engine idle speed by mov- ing the IAC motor pintle in and out of the air control...
Page 1261 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 29 coolant temperature drops to 98°C (208°F). Refer to TACHOMETER—PCM OUTPUT Group 7, Cooling Systems for more information. The powertrain control module (PCM) supplies en- The relay is located in the power distribution cen- gine rpm values to the instrument cluster tachometer ter (PDC) (Fig.
Page 1262 14 - 30 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION The powertrain control module (PCM) monitors air temperature in the intake manifold through the in- take manifold air temperature sensor. The PCM ad- justs injector pulse width and ignition timing to compensate for intake manifold air temperature. Re- fer to Powertrain Control Module (PCM) for more in- formation.
Page 1263 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 31 • The powertrain control module (PCM) pre-posi- • Intake manifold air temperature sensor • Manifold absolute pressure (MAP) sensor tions the idle air control (IAC) motor. • The PCM determines atmospheric air pressure •...
Page 1264 14 - 32 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION • The PCM adjusts ignition timing by increasing DECELERATION MODE and decreasing spark advance. When the engine is at operating temperature, this • The PCM operates the A/C compressor clutch is an Open Loop mode. During hard deceleration, the powertrain control module (PCM) receives the follow- through the clutch relay.
Page 1265 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION 14 - 33 • The PCM opens the ground circuit to the A/C clutch relay to disengage the A/C compressor clutch. This will be done for approximately 15 seconds (if the air conditioning system is operating). If the vehicle has a manual transmission, the up- shift lamp is operated by the PCM.
Page 1266 14 - 34 FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION The fuel pressure regulator used is a vacuum bal- anced, nonadjustable type. The regulator is mounted on the output end of the fuel rail and is connected to intake manifold vacuum. The fuel return tube (to the fuel tank) is connected to the fuel pressure regulator.
Page 1267 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 35 MULTI-PORT FUEL INJECTION (MFI)—GENERAL DIAGNOSIS INDEX page page Automatic Shutdown (ASD) Relay Testing ..46 Manifold Absolute Pressure (Map) Sensor Test . . . 47 Camshaft Position Sensor Test ....46 On-Board Diagnostics (OBD) .
Page 1268 14 - 36 FUEL SYSTEM GENERAL DIAGNOSIS Fig. 6 Ignition Coil—4.0L Engine—Typical Fig. 3 PDC—YJ Models Fig. 7 Distributor and Wiring—2.5L Engine—Typical Fig. 4 PDC—XJ Models Fig. 8 Distributor and Wiring—4.0L Engine—Typical Fig. 5 Ignition Coil—2.5L Engine—Typical (6) Verify that generator output wire, generator Ignition System.
Page 1269 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 37 Fig. 11 CCV System—2.5L Engine Fig. 9 Generator Connector and Output Wire Connections—Typical (7) Inspect the system ground connections at the engine (Fig. 10). For location of system grounds, refer to Group 8, Wiring. Fig.
Page 1270 14 - 38 FUEL SYSTEM GENERAL DIAGNOSIS Fig. 14 Pressure Regulator Vacuum Hose—4.0L Fig. 17 Brake Vacuum Booster Hose—Typical Engine (16) Inspect radiator grille area, radiator fins and air conditioning condenser for restrictions. (17) Verify that intake manifold air temperature sensor wire connector is firmly connected to harness connector (Figs.
Page 1271 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 39 (18) Inspect engine ground strap connections at dash panel and rear cylinder head bolt (Fig. 20). For ground locations, refer to Group 8, Wiring. Fig. 22 Fuel Injector Wire Harness—Typical Fig. 20 Engine Ground Strap Connections—Typical (19) Verify that MAP sensor electrical connector is firmly connected to MAP sensor (Fig.
Page 1272 14 - 40 FUEL SYSTEM GENERAL DIAGNOSIS Fig. 27 Fuel Pump Module Connector and Fuel Hoses—Typical Fig. 25 Oxygen Sensor Location—Typical plugged catalytic convertor. (27) If equipped with automatic transmission, ver- ify that electrical harness is firmly connected to park/ neutral safety switch.
Page 1273 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 41 Fig. 28 Starter Solenoid Connections—Typical PCM SYSTEM SCHEMATICS Powertrain control system schematics for the 2.5L 4-cylinder and 4.0L 6-cylinder engines are shown in figures 29, 30, 31 and 32. These schematics are displayed as a quick refer- ence only.
Page 1274 14 - 42 FUEL SYSTEM GENERAL DIAGNOSIS...
Page 1275 Fig. 30 System Schematic—YJ Models with 4.0L Engine...
Page 1276 Fig. 31 System Schematic—XJ Models with 2.5L Engine...
Page 1277 Fig. 32 System Schematic—XJ Models with 4.0L Engine...
Page 1278 14 - 46 FUEL SYSTEM GENERAL DIAGNOSIS AUTOMATIC SHUTDOWN (ASD) RELAY TESTING SENSOR RESISTANCE (OHMS)—COOLANT TEMPERATURE SENSOR/MANIFOLD AIR To perform a complete test of the ASD relay and its TEMPERATURE circuitry, refer to the DRB scan tool and appropriate Powertrain Diagnostics Procedures manual. To test the relay only, refer to Relays—Operation/Testing in this section of the group.
Page 1279 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 47 Fig. 36 MAP Sensor—Typical Fig. 35 Air Temperature Sensor—4.0L Engine Test the resistance of the wire harness. Do this be- tween the powertrain control module (PCM) wire harness connector terminal-2 and the sensor connec- tor terminal.
Page 1280 14 - 48 FUEL SYSTEM GENERAL DIAGNOSIS EXTENDED IDLE SWITCH TEST OPTIONAL POLICE PACKAGE ONLY OPERATION The extended idle switch is used to raise the en- gine idle speed to approximately 1000 rpm when the shifter is in either the Park or Neutral position. A rocker-type 2-wire switch (extended idle switch) is mounted to the instrument panel.
Page 1281 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 49 (4) Start engine. When the switch on the tool is in the HIGH or LOW position, the light on the tool will flash. This indicates that voltage pulses are being sent to the IAC stepper motor.
Page 1282 14 - 50 FUEL SYSTEM GENERAL DIAGNOSIS RELAYS—OPERATION/TESTING (2) Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value OPERATION (ohms) should be 75 5 ohms for resistor equipped The following operations/tests apply to these relays. relays only: automatic shutdown (ASD), fuel pump (3) Connect the ohmmeter between terminals num- and torque converter clutch.
Page 1283 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 51 (8) Disconnect jumper wires from relay and 12 Volt Certain criteria must be met for a diagnostic trou- power source. ble code (DTC) to be entered into PCM memory. The If continuity or resistance tests did not pass, re- criteria may be a specific range of engine rpm, engine place relay.
Page 1284 14 - 52 FUEL SYSTEM GENERAL DIAGNOSIS INJECTOR DIAGNOSIS—VEHICLE RUNS ROUGH AND/OR HAS A MISS...
Page 1285 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 53 line. However, these could result in a rich or lean ACCESSING DIAGNOSTIC TROUBLE CODES condition causing an oxygen sensor DTC to be stored A stored diagnostic trouble code (DTC) can be dis- in the PCM. played by cycling the ignition key On-Off-On-Off-On Secondary Ignition Circuit: The PCM cannot within three seconds and observing the malfunction...
Page 1286 14 - 54 FUEL SYSTEM GENERAL DIAGNOSIS If the problem is repaired or ceases to exist, the Powertrain Control Module (PCM) cancels the DTC after 51 engine starts. Diagnostic Trouble Codes indicate the results of a failure, but never identify the failed component di- rectly.
Page 1287 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 55 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS Diagnostic DRB Scan Tool Description of Diagnostic Trouble Code Trouble Code No Crank Reference Signal at PCM No crank reference signal detected during en- gine cranking. Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key-on cycles.
Page 1288 14 - 56 FUEL SYSTEM GENERAL DIAGNOSIS DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED Diagnostic DRB Scan Tool Description of Diagnostic Trouble Code Trouble Code 25** Idle Air Control Motor Circuits A shorted condition detected in one or more of the idle air control motor circuits. Injector #1 Control Circuit Injector #1 output driver does not respond properly to the control signal.
Page 1289 FUEL SYSTEM GENERAL DIAGNOSIS 14 - 57 DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED Diagnostic DRB Scan Tool Description of Diagnostic Trouble Code Trouble Code Battery Temp Sensor Volts out of Limit An open or shorted condition exists in the en- gine coolant temperature sensor circuit or a problem exists in the PCM’s battery tempera- ture voltage circuit.
Page 1290 14 - 58 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION MULTI-PORT FUEL INJECTION (MFI)—COMPONENT REMOVAL/INSTALLATION INDEX page page Accelerator Pedal and Throttle Cable ... 58 Fuel Tanks ......62 Air Cleaner Element .
Page 1291 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION 14 - 59 Fig. 5 Clamp Removal Fig. 3 Air Cleaner—XJ Models—Typical Fig. 6 Clamp Installation AIR CLEANER ELEMENT REMOVAL/INSTALLATION (1) Pry back the six clips (YJ Models) or three clips (XJ Models) retaining the air cleaner cover to the air cleaner housing.
Page 1292 14 - 60 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION CAMSHAFT POSITION SENSOR ENGINE COOLANT TEMPERATURE SENSOR For removal/installation procedures, refer to Group The coolant temperature sensor is installed in the 8D, Ignition System. See Camshaft Position Sensor. thermostat housing (Fig. 9). INTAKE MANIFOLD AIR TEMPERATURE SENSOR The intake manifold air temperature sensor is in- stalled into the intake manifold plenum (Figs.
Page 1293 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION 14 - 61 To release fuel pressure, refer to the Fuel Delivery System section of this group. See Fuel System Pres- sure Release. REMOVAL The fuel pressure regulator is located at the front of the fuel rail (Fig 12). It is held to the fuel rail (mounted vertically) with a clamp and bolt (Fig.
Page 1294 14 - 62 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION FUEL RAIL ASSEMBLY LINES, FUEL FILTER OR FUEL INJECTOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REMOVAL Refer to the Fuel Delivery System section of this WARNING: THE FUEL SYSTEM IS UNDER CON- group.
Page 1295 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION 14 - 63 INTAKE MANIFOLD Refer to Group 11, Exhaust System and Intake Manifold for removal/installation procedures. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The MAP sensor is located on the dash panel near the rear of the engine cylinder head (valve) cover (Fig.
Page 1296 14 - 64 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION Fig. 20 PCM Location—YJ Models Fig. 18 Power Steering Pressure Switch—XJ Models (2) YJ Models Only: Remove the windshield (2) Place a small container or shop towel beneath washer fluid tank. the switch to collect any excess fluid. (3) Loosen the 60-Way connector mounting bolt (3) Remove the switch.
Page 1297 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION 14 - 65 Fig. 23 TPS Location—2.5L Engine Fig. 21 Cables at Throttle Body Fig. 24 TPS Location—4.0L Engine Fig. 22 Throttle Body—Removal/Installation— REMOVAL Typical (1) Disconnect TPS electrical connector. INSTALLATION (2) Remove TPS mounting bolts. (1) Install throttle body and new gasket.
Page 1298 14 - 66 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION VEHICLE SPEED SENSOR The vehicle speed sensor (Fig. 28) is located on the extension housing of the transmission on 2WD mod- els. It is located on the transfer case on 4WD models. REMOVAL Fig.
Page 1299 FUEL SYSTEM SPECIFICATIONS 14 - 67 speedometer pinion gear adapter (Fig. 29). Do not re- verify speed sensor is fully seated (mounted move the gear adapter from the transmission. flush) to speedometer pinion gear adapter. (3) Tighten sensor mounting bolt to 2.2 N m (20 in. INSTALLATION lbs.) torque.
Page 1301 PROPELLER SHAFTS 16 - 1 PROPELLER SHAFTS CONTENTS page page GENERAL INFORMATION ....1 TORQUE SPECIFICATIONS ....15 SERVICE DIAGNOSIS .
Page 1302 16 - 2 PROPELLER SHAFTS shaft must be able to change operating angles when going over various road surfaces. This is done through universal joints, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion (Fig. 1,2). Tubular propeller shafts are balanced by the man- ufacturer with weights spot welded to the tube.
Page 1303 PROPELLER SHAFTS 16 - 3 SERVICE DIAGNOSIS INDEX page page Runout ........4 Universal Joint Angle Measurement .
Page 1304 16 - 4 PROPELLER SHAFTS (10) Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. (11) Install the wheel and tires. Lower the vehicle. (12) If the amount of vibration remains unaccept- able, apply procedures at the front end of the propel- ler shaft.
Page 1305 PROPELLER SHAFTS 16 - 5 • Have at least a 1/2 degree continuous operating (propeller shaft) angle Engine speed (R.P.M.) is the main factor though in determining maximum allowable operating angles. As a guide to maximum normal operating angles re- fer to the chart listed (Fig.
Page 1306 16 - 6 PROPELLER SHAFTS ADJUSTMENT AT AXLE WITH LEAF SPRINGS Adjust the pinion shaft angle at the springs with tapered shims (Fig. 9). Install tapered shims between the springs and axle pad to correct the angle. Refer to Group 3, Rear Suspension and Axle for additional information.
Page 1307 PROPELLER SHAFTS 16 - 7 ADJUSTMENT—XJ FRONT SHAFT Adjust the pinion gear angle at the lower suspen- sion arms with shims (Fig. 10). Adding shims will de- crease the pinion gear shaft angle but will increase the caster angle. The pinion gear shaft angle has pri- ority over the caster angle.
Page 1308 16 - 8 PROPELLER SHAFTS SERVICE PROCEDURES PRECAUTIONS Use exact replacement hardware for attaching the propeller shafts. Exact replacement will ensure safe operation. The specified torque must always be ap- plied when tightening the fasteners. Put reference marks on the propshaft yoke and axle or transmission yoke before service (Fig.
Page 1309 PROPELLER SHAFTS 16 - 9 each end of the propeller shaft. These marks will be used for installation reference (Fig. 4). Fig. 4 YJ Front Propeller Shaft (3) Remove the U-joint strap bolts at the pinion shaft yoke. (4) Disconnect the propeller shaft at the transfer Fig.
Page 1310 16 - 10 PROPELLER SHAFTS UNIVERSAL JOINT REPLACEMENT PRECAUTIONS (5) Set the yoke in an arbor press or vise with a large socket beneath it. Position the yoke with the lube fitting It is very important to put reference marks on the pointing up (if equipped).
Page 1311 PROPELLER SHAFTS 16 - 11 Fig. 6 Install Bearing On Trunnion (7) Install the propeller shaft. Refer to Propeller Fig. 4 Press Out Remaining Bearing Shaft Replacement in this Group. DOUBLE CARDAN (CV) REMOVAL/DISASSEMBLY Cardan universal joints are not serviceable. If worn or leaking, they must be replaced as a unit.
Page 1312 16 - 12 PROPELLER SHAFTS (4) Press the bearing assembly partially from the (6) Flip assembly and repeat steps 4 and 5 for removing outboard side of the center yoke, enough to grasp by the opposite side bearing. This will then allow removal vise jaws (Fig.
Page 1313 PROPELLER SHAFTS 16 - 13 (2) Place a bearing assembly in a tube yoke hole (4) Flip the tube yoke and bearing assembly instal- and over a trunnion. Keep the needle bearings up- lation on the opposite trunnion. Install a snap ring right in the bearing assembly (Fig.
Page 1314 16 - 14 PROPELLER SHAFTS (6) Install the centering kit assembly inside the (8) Press the remaining two bearing assemblies center yoke making sure the spring is in place (Fig. into place and install snap rings (Fig. 18). 16). Fig. 18 Press In Bearing Assembly Fig.
Page 1315 PROPELLER SHAFTS 16 - 15 (10) Check for proper assembly. Flex the CV joint (11) Install the propeller shaft. Refer to Propeller beyond center, it should snap over-center in both di- Shaft Replacement in this Group. rections when correctly assembled (Fig. 20). Fig.
Page 1317 The movement of these parts, while turning or parking, is aided by hydraulic pressure and flow sup- Jeep vehicles can have either a manual or power plied by the pump. Manual steering is always avail- steering system (Fig. 1). A recirculating-ball type able at times when the engine is not running or in steering gear is used for both systems.
Page 1318 4.0L engine have the reservoir attached to the pump body with spring clips. STEERING COLUMNS Two general types of steering columns are installed on Jeep vehicles: a fixed, non-tilt column and a tilt Fig. 4 Steering Columns column (Fig. 4). The ignition key/lock cylinder is located in the The center, slip-type intermediate shaft is attached steering column.
Page 1319 STEERING 19 - 3 POWER STEERING SYSTEM DIAGNOSIS PUMP PRESSURE TEST CAUTION: The following test procedure involves testing maximum pump pressure output and flow (1) Check belt tension and adjust as necessary. control valve operation. Do not leave valve closed (2) Disconnect high pressure hose at gear or pump.
Page 1320 19 - 4 STEERING POWER STEERING SYSTEM DIAGNOSIS...
Page 1321 STEERING 19 - 5 POWER STEERING SYSTEM DIAGNOSIS...
Page 1322 19 - 6 STEERING POWER STEERING SYSTEM DIAGNOSIS...
Page 1323 STEERING 19 - 7 POWER STEERING SYSTEM DIAGNOSIS...
Page 1324 19 - 8 STEERING POWER STEERING SYSTEM DIAGNOSIS...
Page 1325 STEERING 19 - 9 POWER STEERING SYSTEM DIAGNOSIS...
Page 1326 19 - 10 STEERING PUMP LEAKAGE DIAGNOSIS GEAR LEAKAGE DIAGNOSIS...
Page 1327 STEERING 19 - 11 POWER STEERING PUMP INDEX page page Drive Pulley Replacement ....13 Pump Replacement ......12 Flow Control Valve Fitting O-Ring Seal .
Page 1328 19 - 12 STEERING Fig. 2 Power Steering Hose—XJ 4 Cylinder (7) After installation, inspect and test for fluid leaks. PUMP REPLACEMENT REMOVAL CAUTION: The drive belt tension must be released before removing the pump. If the belt is not loos- ened, the pump pulley could be damaged.
Page 1329 STEERING 19 - 13 Fig. 4 Pump Mounting—6 Cylinder INSTALLATION (2) Remove the drive pulley with Puller C-4333 (1) Install 3 front bracket-to-pump bolts. Tighten (Fig. 5). to 28 N m (21 ft. lbs.) torque. (2) Install pulley on pump. Refer to Drive Pulley Replacement in this section (Fig.
Page 1330 19 - 14 STEERING Fig. 8 Remove Reservoir Clips—Typical Fig. 6 Install Drive Pulley—Typical (2) Be sure tool and pulley remain aligned and NOT cocked with the pump shaft. (3) Press the pulley on flush with end of pump shaft (Fig. 7). (4) Install power steering pump.
Page 1331 STEERING 19 - 15 (2) Remove fitting from pump housing (Fig. 10). POWER STEERING PUMP—INITIAL OPERATION Prevent flow control valve and spring from CAUTION: The fluid level should be checked with sliding out of housing bore. engine off to prevent injury from moving compo- nents.
Page 1332 19 - 16 STEERING STEERING LINKAGE—XJ INDEX page page Drag Link ....... 16 Steering Damper .
Page 1333 STEERING 19 - 17 Fig. 2 Steering Linkage (4) Remove the steering damper ball stud from the drag link with a puller tool. INSTALLATION (1) Install the steering damper to the axle bracket and drag link. (2) Install the steering damper bolt in the axle bracket.
Page 1334 19 - 18 STEERING (3) Install drag link ball stud to pitman arm (Fig. 4). Install and tighten nut to 74 N m (55 ft. lbs.) torque. Install a new cotter pin. Fig. 4 Pitman Arm Removal (2) Install the washer and nut on the shaft. Tighten the nut to 251 N m (185 ft.
Page 1335 STEERING 19 - 19 STEERING LINKAGE—YJ INDEX page page Drag Link ....... 20 Steering Damper .
Page 1336 19 - 20 STEERING (3) If necessary, loosen the end clamp bolts and re- (2) Remove the steering damper retaining nut and move the tie rod end from the tube. bolt from the axle bracket (Fig. 2). (3) Remove the cotter pin and nut from the ball INSTALLATION stud at the tie rod (Fig.
Page 1337 STEERING 19 - 21 RECIRCULATING BALL POWER STEERING GEAR INDEX page page Adjuster Plug Assembly Replacement ..29 Pitman Shaft Seals—In Car Replacement ..23 Check Valve Replacement .
Page 1338 Fig. 1 Power Steering Gear...
Page 1339 STEERING 19 - 23 PITMAN SHAFT SEALS—IN CAR REPLACEMENT REMOVAL (1) Remove pitman arm from gear. Refer to Pitman Arm Removal in Steering Linkage. (2) Clean exposed end of pitman shaft and hous- ing. Use a wire brush to clean the shaft splines. (3) Remove retaining ring with snap ring pliers (Fig.
Page 1340 19 - 24 STEERING Fig. 6 Steering Gear Mounting—XJ Fig. 4 Coupler Shaft—XJ Fig. 5 Coupler Shaft—YJ (5) Remove the steering gear retaining bolts and nuts. Remove the steering gear from the vehicle (Fig. 6, 7). INSTALLATION Fig. 7 Steering Gear Mounting—YJ (1) Align the column coupler shaft to steering gear.
Page 1341 STEERING 19 - 25 • SECOND - over-center preload adjustment (4) Measure back (counterclockwise) 13 mm (0.50 in) and mark housing (Fig. 10). WORM THRUST BEARING PRELOAD ADJUSTMENT (1) Remove adjuster plug locknut (Fig. 8). Fig. 10 Remarking The Housing (5) Rotate adjustment cap back (counterclockwise) with spanner wrench until hole is aligned with the second mark (Fig.
Page 1342 19 - 26 STEERING (2) Starting at either stop turn the stub shaft back 1/2 the total number of turns. This is the center of the gear travel (Fig. 12). Fig. 13 Checking Over-center Rotation Torque Fig. 12 Steering Gear Centered (3) Turn the pitman shaft adjuster screw back (COUNTERCLOCKWISE) until extended, then turn back in (CLOCKWISE) one full turn.
Page 1343 STEERING 19 - 27...
Page 1344 19 - 28 STEERING PITMAN SHAFT AND SIDE COVER REPLACEMENT (3) Install gasket to side cover and bend tabs around edges of side cover. REMOVE (4) Install pitman shaft assembly and side cover to (1) Remove steering gear from vehicle. Refer to housing.
Page 1345 STEERING 19 - 29 (2) Install pitman arm onto steering gear. Refer to CAUTION: Do not turn stub shaft any farther than necessary. The recirculating balls will drop out of Steering Linkage in this Group. the rack piston circuit and fall inside the rack pis- ADJUSTER PLUG ASSEMBLY REPLACEMENT ton chamber.
Page 1346 19 - 30 STEERING (4) Remove bearing spacer, races and thrust bear- (1) Install needle bearing into adjuster plug with ing (Fig. 21). tool C-4177 and handle C-4171. (2) Apply white petroleum grease on lip seal. In- stall lip seal into adjuster plug with tool C-4177 and handle C-4171.
Page 1347 STEERING 19 - 31 Fig. 26 Remove and Install Stub Shaft Fig. 24 Tighten Lock Nut DISASSEMBLE (1) Remove adjuster plug, refer to Adjuster Plug Assembly Replacement. (2) Remove stub shaft and valve assembly (Fig. 25). Fig. 27 Remove and Install Spool •...
Page 1348 19 - 32 STEERING INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section. RACK PISTON AND WORM SHAFT REPLACEMENT REMOVE (1) Remove steering gear from vehicle. Refer to Power Steering Gear Replacement in this section. DISASSEMBLE (1) Remove pitman shaft and side cover.
Page 1349 STEERING 19 - 33 Fig. 33 Installing Balls in Rack Piston Fig. 31 Remove and Install Rack Piston There are 24 balls in the rack piston circuit, 12 are black and 12 are silver (Chrome). The black rack piston balls are smaller than the sil- ver balls.
Page 1350 19 - 34 STEERING the stub shaft COUNTERCLOCKWISE. PITMAN SHAFT SEALS AND BEARING • The rack piston will be forced onto the tool and REPLACEMENT hold the rack piston balls in place. (7) Install the races and thrust bearing to worm REMOVE shaft (Fig.
Page 1351 STEERING 19 - 35 Fig. 39 Pitman Shaft Seal Installation Fig. 37 Needle Bearing Removal INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section. CHECK VALVE REPLACEMENT REMOVE (1) Remove steering gear from vehicle. Refer to Power Steering Gear Replacement in this section.
Page 1352 19 - 36 STEERING POWER STEERING GEAR SPECIFICATIONS...
Page 1353 INFORMATION INSPECTION (1) Inspect the condition of the steering gear lubri- The manual steering gear installed on Jeep vehi- cant. If contaminated (contains metal particles), re- cles (Fig. 1) has a variable steering ratio. move and overhaul the steering gear.
Page 1354 19 - 38 STEERING MANUAL STEERING SYSTEM DIAGNOSIS...
Page 1355 STEERING 19 - 39 (2) Wrap a single layer of plastic tape around the (2) Turn the over center adjusting screw in to re- pitman shaft threads and splines. This will protect move all lash between the ball nut and pitman shaft the replacement seals during installation.
Page 1356 19 - 40 STEERING Fig. 2 Manual Steering Gear—Exploded View...
Page 1357 STEERING 19 - 41 Fig. 3 Shaft Seal Removal Fig. 4 Wormshaft & Ball Nut (3) Hold the ball nut over a cloth. Remove the re- (4) Divide the remaining 48 recirculating balls into maining recirculating balls by rotating the worm- two groups and install 24 balls in each ball nut cir- shaft back and forth.
Page 1358 19 - 42 STEERING (6) Lubricate the wormshaft threads with chassis lubricant. Rotate the shaft to move it in and out of the ball nut and distribute the lubricant. (7) Lubricate the wormshaft upper bearing with chassis lubricant and install it on the wormshaft. WORMSHAFT BEARING ADJUSTMENT CAP DISASSEMBLY (1) Pry out and remove the wormshaft lower bear-...
Page 1359 STEERING 19 - 43 (5) If the shaft fit is loose but it is not visibly worn, trial fit a replacement pitman shaft in the housing shaft bore. If the replacement shaft also has a loose fit, replace the housing. However, if the re- placement pitman fits properly, replace the original pitman shaft.
Page 1360 19 - 44 STEERING (6) Install the wormshaft bearing adjustment cap terclockwise until cover is tight against the gasket, in the housing and tighten it only enough to remove then loosen the screw 1/2 rotation. the wormshaft end-play. (15) Tighten the cover bolts to 61 N m (45 ft. lbs.) (7) Install the locknut on the wormshaft bearing torque.
Page 1361 STEERING 19 - 45 Fig. 14 Over-center Adjustment Fig. 15 Coupler Shaft—XJ (4) Hold pitman shaft adjustment screw and tighten adjuster lock nut to 34 N m (25 ft. lbs.) torque. INTERMEDIATE (COUPLER) SHAFT REMOVAL (1) Place the front wheels in the straight ahead po- sition.
Page 1362 19 - 46 STEERING (4) Remove the steering gear retaining bolts and INSTALLATION nuts. Remove the steering gear from the vehicle (Fig. (1) Align the column coupler shaft to steering gear. 17, 18). Refer to Column Coupler installation in this section. (2) Position the steering gear (and bracket) on the frame rail and install the bolts.
Page 1363 STEERING 19 - 47 STEERING COLUMN GENERAL SERVICE—XJ INDEX page Airbag System ......47 AIRBAG SYSTEM WARNING: REPLACE AIRBAG SYSTEM COMPO- NENTS WITH PARTS SPECIFIED IN THE CHRYSLER...
Page 1364 The airbag system is a standard equipment safety THE FASTENERS, SCREWS, AND BOLTS, ORIG- device on XJ (Cherokee) models. It is designed to pro- INALLY USED FOR THE AIR BAG COMPONENTS, tect the driver from serious injury, caused by a fron- HAVE SPECIAL COATINGS.
Page 1365 STEERING 19 - 49 AIRBAG MODULE REMOVE—INSTALL WARNING: THIS AIRBAG SYSTEM IS A SENSITIVE, COMPLEX MECHANICAL UNIT. BEFORE ATTEMPT- ING TO REMOVE OR INSTALL THE AIRBAG SYS- RELATED STEERING WHEEL STEERING COLUMN COMPONENTS YOU MUST FIRST DISARM THE AIRBAG FIRING MECHANISM. FAILURE TO DO SO COULD RESULT IN ACCIDEN- TAL DEPLOYMENT AND POSSIBLE PERSONAL IN- JURY.
Page 1366 19 - 50 STEERING Fig. 5 Airbag Module Remove/Install (2) Disconnect the battery negative (ground) cable (6) Remove the steering wheel retaining nut. Score and isolate. or paint alignment marks on the column shaft and (3) Disarm the airbag (refer to group 8M, Electri- steering wheel (if none exist) for installation refer- cal for proper and safe procedures).
Page 1367 STEERING 19 - 51 Fig. 8 Upper and Lower Steering Column Shroud CENTERING PROCEDURE If the rotating tape within the clockspring is not positioned properly, the clockspring may fail during use. The following procedures MUST BE USED to center the clockspring; Fig.
Page 1368 19 - 52 STEERING (4) From the end of travel, rotate the rotor 2 1/2 full turns in the COUNTER CLOCKWISE direction. The horn wire should end up at the top and the squib wire at the bottom (Fig. 9). (5) Install the steering wheel and air bag module, refer to Steering Wheel Installation.
Page 1369 STEERING 19 - 53 Fig. 14 Halo Light And Key In Buzzer Wiring Fig. 15 Multi Function Switch Wiring Connection Connection (2) Ensure the ground clip is on the left spacer slot (14) Remove the Interlock cable from the steering (Fig.
Page 1370 19 - 54 STEERING Fig. 17 Ground Clip & Spacer Installation Fig. 20 Wiring Harness Connection To Clock Spring And Ignition Switch (9) Be sure both spacers are fully seated in the col- umn support bracket. Tighten the column panel bracket support nuts to 12 N m (105 in.
Page 1371 STEERING 19 - 55 Fig. 3 Observe Cautions Fig. 1 Steering Column Non-Serviceable Components (1) Remove the ignition switch from the steering column. Refer to Group 8D Ignition System. (2) Using a key cylinder, check the turning effort of the switch. •...
Page 1372 19 - 56 STEERING Fig. 1 Ignition Interlock Cable Routing Fig. 2 Ignition Key Cylinder Actuation (2) Remove two screws retaining the interlock mechanism to the column (Fig. 3). Unsnap the mech- anism from column. (3) Remove the center console and related trim. Refer to Group 23, Body.
Page 1373 STEERING 19 - 57 (9) Install the center console and related trim. Re- fer to Group 23, Body. (10) Test the park-lock cable operation. (11) Load the steering column up to the bracket. Refer to Column Assembly Replacement in this group.
Page 1374 19 - 58 STEERING STEERING COLUMN—YJ INDEX page page Assembly ....... 63 Disassembly—Column or Console Shift .
Page 1375 STEERING 19 - 59 (1) Make sure the front wheels are in the straight (9) Disconnect the following items from the steer- ahead position. ing column connectors: • Ignition switch wire harness (2) Disconnect the negative (ground) cable from the •...
Page 1376 19 - 60 STEERING (6) Column shift vehicles, install the shift cable REMOVE THE STEERING SHAFT RETAINING SNAP grommet on the shift lever. RING WITHOUT USING LOCKPLATE COMPRESSOR (7) Install and tighten the toe plate to floor pan C-4156. bolts/nuts to 21.5 N m (192 in. lbs.) torque (Fig. 5). (4) Compress lockplate with...
Page 1377 STEERING 19 - 61 Fig. 3 Steering Column Disassembly Fig. 5 Turn Signal Switch Retaining Screw (13) Remove the key warning buzzer switch and contacts as a unit (Fig. 6). Use needle-nose pliers or a paper clip bent at a right angle (90 degrees). Fig.
Page 1378 19 - 62 STEERING Fig. 7 Key/lock Cylinder Removal (15) Remove the ignition switch and the dimmer switch (Fig. 8) from the lower end of the steering col- umn. Fig. 9 Key/Lock Cylinder Housing Fig. 8 Ignition Switch & Dimmer Switch Proceed to Column Shift Disassembly Proce- Fig.
Page 1379 STEERING 19 - 63 ASSEMBLY WARNING: USE ONLY THE ORIGINAL OR EXACT REPLACEMENT SCREWS, BOLTS AND NUTS TO ASSEMBLE THE STEERING COLUMN. INCORRECT SCREW OR BOLT LENGTH COULD PREVENT THE COLUMN FROM COMPRESSING WITH IMPACT (FRONT-END COLLISION). ALL FASTENERS USED FOR ASSEMBLY MUST BE TIGHTENED WITH THE CORRECT TORQUE.
Page 1380 19 - 64 STEERING Fig. 16 Key/Lock Cylinder Housing Fig. 14 Lock Bolt & Lock Rack (10) Install the gear selector lever housing and shroud on the upper end of the steering column jacket. Rotate the housing and ensure that the bear- ing is properly seated.
Page 1381 STEERING 19 - 65 Fig. 17 Key/Lock Cylinder Installation Fig. 18 Canceling Cam Position (6) Position the turn signal switch and wire har- ness in the cylinder housing. Fold the wires against the connector. Route the connector down through the steering column jacket.
Page 1382 19 - 66 STEERING TILT STEERING COLUMN DISASSEMBLY (1) Remove the steering column from the vehicle, if necessary. Refer to the removal procedure. (2) If the column is removed for service, fabricate a support fixture to clamp it in a vise (Fig. 1). Fig.
Page 1383 STEERING 19 - 67 Fig. 3 Turn Signal Switch Wire Harness Connector Fig. 5 Key Warning Buzzer/Contacts Removal Fig. 6 Key/lock Cylinder Removal (23) Remove the screws that attach the key/lock cylinder housing cover to the steering column jacket. Remove the cover. (24) Remove the upper bearing race and the bear- Fig.
Page 1384 19 - 68 STEERING Fig. 9 Retainer/Guide/Spring Removal Fig. 7 Ignition Switch & Dimmer Switch Fig. 10 Pivot Pin Removal Fig. 8 Steering Shaft Bearing Race & Seat (27) Position the steering column in the center, non-tilt position. (28) Remove the support pivot pins with Pivot Pin Remover C-4016 (Fig.
Page 1385 STEERING 19 - 69 (31) Remove the lock sector spring retaining screw (34) Remove the tilt-release lever pin from the key/ and then remove the spring (Fig. 12). Rotate the lock cylinder housing with a standard pin punch (Fig. spring in a clockwise direction to remove it from the 14).
Page 1386 19 - 70 STEERING replaced, remove them with a hammer and punch. (40) Remove the retaining screws and shift gate Discard the bearings and races after removal. They from the steering column support. are not reusable. (41) Remove the retainer and the bearing from the (37) Remove the steering shaft from the upper end lower end of the steering column.
Page 1387 STEERING 19 - 71 (45) If equipped with a column shift: must engage the shift tube inner shoulder. The tool • Remove the wave washer and the shift tube spring guide must be seated in the shift tube (Fig. 21). •...
Page 1388 19 - 72 STEERING (9) Install the shift tube thrust washer and the re- tainer over the spring. Engage the retainer lock tabs tainer plate snap ring. with the housing lugs by pressing the retainer down- (10) Install the lower bearing in the steering col- ward and turning clockwise with a screwdriver.
Page 1389 STEERING 19 - 73 (36) If equipped, install the cruise control wire har- ness. Install the turn signal stalk by pushing it straight into the column. (37) Insert the hazard warning knob in the hazard warning switch and press it inward. Align and install the turn signal switch retaining screws.
Page 1390 19 - 74 STEERING STEERING RHD GENERAL SERVICE PROCEDURE INFORMATION REMOVAL Right hand drive service procedures and torque (1) Place a drain pan under the pump and gear. (2) Disconnect the pressure and return line from specifications involving steering; linkage, gear and column are the same as left hand drive vehicles ex- the steering gear (Fig.
Page 1391 STEERING 19 - 75 Fig. 3 Pressure And Return Lines Fig. 4 Fluid Lines At Pump (2) Install pressure and return line on the pump (4) Remove pressure and return line bracket at belt tensioner (Fig. 5). and gear (Fig. 2, 3, 4). (3) Align the pressure and return line bracket to INSTALLATION the tensioner bracket.
Page 1392 19 - 76 STEERING Fig. 8 Power Steering Pump Mounting Fig. 6 Belt Tensioner Fig. 9 Front Bracket (2) Remove belt tension, turn tensioner clock-wise and slip belt off pulley (Fig. 6). (3) Remove the screws retaining front bracket and pump to the rear bracket (Fig.
Page 1393 STEERING 19 - 77 Fig. 10 Rear Bracket (Front View) Fig. 11 Rear Bracket (Side View) INSTALLATION (5) Loose assemble screws through front bracket, pump and into rear bracket. (1) Install the rear bracket to engine. Install (6) Install screws that attach the front bracket to screws finger tight.
Page 1394 19 - 78 STEERING TORQUE SPECIFICATIONS STEERING LINKAGE—YJ POWER STEERING GEAR POWER STEERING PUMP MANUAL STEERING GEAR STEERING COLUMN—XJ STEERING LINKAGE—XJ STEERING COLUMN—YJ...
Page 1395 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page 30RH/32RH AUTOMATIC TRANSMISSION ..67 NP231 TRANSFER CASE ....283 AW 4 AUTOMATIC TRANSMISSION .
Page 1396 21 - 2 AX 4/5 MANUAL TRANSMISSION TRANSMISSION IDENTIFICATION The AX 4/5 identification code is on the bottom sur- face of the transmission case near the fill plug (Fig. 2). The first number is year of manufacture. The second and third numbers indicate month of manufacture. The next series of numbers is the transmission serial num- ber.
Page 1397 AX 4/5 MANUAL TRANSMISSION 21 - 3 happens when the container delivery mechanism is im- Worn or damaged synchro rings can cause gear clash properly calibrated. Always check the lubricant level af- when shifting into any forward gear. In some new or re- ter filling to avoid an under fill condition.
Page 1398 21 - 4 AX 4/5 MANUAL TRANSMISSION (7) Disconnect transfer case shift linkage at trans- fer case. (8) Disconnect vehicle speed sensor wires and transfer case vent hose. (9) Remove slave cylinder from clutch housing. (10) Disconnect transmission shift lever as follows: (a) Lower transmission-transfer case assembly approximately 7-8 cm (3 in.) for access to shift le- ver.
Page 1399 AX 4/5 MANUAL TRANSMISSION 21 - 5 (21) Remove clutch release bearing, release fork TRANSMISSION DISASSEMBLY AND OVERHAUL and retainer clip. (22) Remove clutch housing from transmission. ADAPTER HOUSING AND FRONT BEARING RETAINER REMOVAL TRANSMISSION INSTALLATION (1) Drain transmission lubricant. (1) Install clutch housing on transmission.
Page 1400 21 - 6 AX 4/5 MANUAL TRANSMISSION (6) Remove shift arm set bolt (Fig. 3) and remove bolt and lockplate. Fig. 5 Removing Bearing Retainer Snap Ring (11) Remove front bearing retainer and intermedi- ate plate by tapping them loose with plastic mallet Fig.
Page 1401 AX 4/5 MANUAL TRANSMISSION 21 - 7 (2) Remove threaded plugs from intermediate plate. Then remove lock ball and spring from plug holes with pencil magnet (Fig. 8). (3) Remove shift fork pins with punch and hammer (Fig. 9). Fig. 7 Positioning Intermediate Plate In Vise Fig.
Page 1402 21 - 8 AX 4/5 MANUAL TRANSMISSION (5) Pull No. 4 shift rail outward and remove lock balls and pin (Fig. 11). Fig. 13 Removing No. 5 Shift Rail And Shift Head Fig. 11 Removing No. 4 Shift Rail, Lock Balls And (6) Remove No.
Page 1403 AX 4/5 MANUAL TRANSMISSION 21 - 9 (10) Remove shift rail No. 2 and shift forks 1 and 2 (12) Remove reverse shift arm and fork (Fig. 18). (Fig. 16). Fig. 16 Removing Shift Forks And No. 2 Shift Rail (11) Remove reverse idler gear and shaft (Fig.
Page 1404 21 - 10 AX 4/5 MANUAL TRANSMISSION (2) Engage two synchro sleeves to lock mainshaft (4) Remove fifth spline gear, synchronizer and gears (Fig. 20). counter fifth gear with 2-, or 3-jaw puller (Fig. 22). Fig. 22 Removing Fifth Gear Assembly (5) Remove spacer and remove lock ball with pencil magnet (Fig.
Page 1405 AX 4/5 MANUAL TRANSMISSION 21 - 11 (6) Remove reverse shift arm bracket (Fig. 24). (8) Remove rear bearing snap ring (Fig. 26). Fig. 24 Removing Reverse Shift Arm Bracket Fig. 26 Removing Rear Bearing Snap Ring (7) Remove rear bearing retainer bolts with appro- (9) Tap intermediate plate with plastic mallet and priate size torx bit and remove retainer (Fig.
Page 1406 21 - 12 AX 4/5 MANUAL TRANSMISSION (12) Measure thrust clearance of output shaft (14) Press fifth gear, rear bearing, first gear and gears (Fig. 28). Clearance should be 0.10 - 0.25 mm inner race off output shaft (Fig. 30). (0.004 - 0.010 in.).
Page 1407 AX 4/5 MANUAL TRANSMISSION 21 - 13 (18) Press 1-2 synchronizer and second gear off output shaft (Fig. 32). Fig. 34 Removing 3-4 Synchronizer And Third Gear CLEANING AND INSPECTION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with Fig.
Page 1408 21 - 14 AX 4/5 MANUAL TRANSMISSION Fig. 37 Checking Output Shaft Runout Fig. 35 Checking Shaft And Bearing Race Flange Thickness Fig. 38 Checking Gear-To-Race Clearance Fig. 36 Checking Shaft And Race Diameters...
Page 1409 AX 4/5 MANUAL TRANSMISSION 21 - 15 Install the needle bearings and the second, third Check shift fork-to-synchronizer hub clearance with and counter fifth gears on the output shaft. Then a feeler gauge (Fig. 41). Replace the fork if clearance check oil clearance between the gears and shaft with exceeds 1.0 mm (0.039 in.).
Page 1410 21 - 16 AX 4/5 MANUAL TRANSMISSION TRANSMISSION ASSEMBLY AND ADJUSTMENT Lubricate the transmission components with Mopar 75W-90, GL 5 gear lubricant during assembly. Use petroleum jelly to lubricate seal lips and/or hold parts in place during installation. Refer to the Counter Gear Comparison Chart (Fig.
Page 1411 AX 4/5 MANUAL TRANSMISSION 21 - 17 (2) Secure front bearing with thickest snap ring ASSEMBLING OUTPUT SHAFT, INPUT SHAFT that will fit in groove (Fig. 43). AND COUNTER GEAR (3) Press front bearing on counter gear. Secure (1) If front bearing was removed from input shaft, bearing with thickest snap ring that will fit in ring press new bearing on shaft (Fig.
Page 1412 21 - 18 AX 4/5 MANUAL TRANSMISSION Fig. 47 Synchronizer Identification Fig. 45 Oil Seal Installation Fig. 48 Installing Third Gear And 3-4 Synchronizer Fig. 46 Installing Reverse Shaft Pin...
Page 1413 AX 4/5 MANUAL TRANSMISSION 21 - 19 (9) Verify third gear thrust clearance with feeler gauge (Fig. 49). Clearance should be 0.10 - 0.25 mm (0.004 - 0.010 in.). Fig. 49 Checking Third Gear Clearance Fig. 51 Installing First Gear And Lock Ball (10) Assemble second gear, gear needle bearing, (13) Press rear bearing on shaft (Fig.
Page 1414 21 - 20 AX 4/5 MANUAL TRANSMISSION (16) Press fifth gear on output shaft (Fig. 55). Fig. 53 Installing Output Shaft Rear Bearing (15) Check first-second gear thrust clearance (Fig. Fig. 55 Installing Output Shaft Fifth Gear 54). Standard clearance is 0.10 - 0.25 mm (0.004 - (17) Install fifth gear snap ring (Fig.
Page 1415 AX 4/5 MANUAL TRANSMISSION 21 - 21 Fig. 57 Installing Input Shaft Bearing Rollers Fig. 58 Installing Output Shaft In Intermediate Plate Fig. 56 Selecting/Installing Fifth Gear Snap Ring...
Page 1416 21 - 22 AX 4/5 MANUAL TRANSMISSION (21) Install counter gear in intermediate plate (Fig. (23) Install reverse shift arm (Fig. 61). Tighten at- 59). taching bolt to 18 N m (13 ft. lbs.) torque. Fig. 61 Installing Reverse Shift Fork Fig.
Page 1417 AX 4/5 MANUAL TRANSMISSION 21 - 23 (26) On AX 5, install assembled gear and synchro- nizer on counter shaft (Fig. 63). Fig. 64 Installing Fifth Gear (AX 5) Fig. 63 Fifth Gear And Synchronizer Installation (AX 5) (27) Install remaining synchronizer ring and spline fifth gear (Fig.
Page 1418 21 - 24 AX 4/5 MANUAL TRANSMISSION Fig. 66 Shift Components...
Page 1419 AX 4/5 MANUAL TRANSMISSION 21 - 25 SHIFT MECHANISM ASSEMBLY AND INSTALLATION When assembling the shift mechanism, refer to Figure 66 for component details and loca- tion. (1) Install reverse shift arm. Then seat shift fork in bracket (Fig. 67). Fig.
Page 1420 21 - 26 AX 4/5 MANUAL TRANSMISSION Fig. 70 Interlock Ball And Pin Position...
Page 1421 AX 4/5 MANUAL TRANSMISSION 21 - 27 (6) Insert first interlock pin in intermediate plate (8) Slide No. 1 rail through 1-2 shift fork (Fig. 73). (Fig. 71). Use pencil magnet and screwdriver to in- stall pin. Fig. 73 Installing No. 1 Shift Rail Fig.
Page 1422 21 - 28 AX 4/5 MANUAL TRANSMISSION (10) Install interlock pin in No. 3 shift rail (Fig. (12) Assemble reverse shift head and No. 5 shift 75). rail. (13) Install No. 5 shift rail in intermediate plate and engage shift head on No. 3 shift rail (Fig. 77). Fig.
Page 1423 AX 4/5 MANUAL TRANSMISSION 21 - 29 (15) Shift fifth gear synchronizer sleeve rearward (17) Install shift rail lock ball with pencil magnet to lock it (Fig. 79). and screwdriver (Fig. 81). Fig. 79 Locking Fifth Synchronizer (16) On AX 5, install fifth-reverse shift fork in syn- chronizer sleeve.
Page 1424 21 - 30 AX 4/5 MANUAL TRANSMISSION (20) Install new shift rail C-rings (Fig. 83). ASSEMBLING GEARTRAIN AND TRANSMISSION CASE (1) Remove intermediate plate from vise. (2) Install new gaskets on intermediate plate. (3) Install transmission case on intermediate plate (Fig.
Page 1425 AX 4/5 MANUAL TRANSMISSION 21 - 31 (5) Install new gasket on front bearing retainer (8) Install shift arm lock plate with pliers (Fig. 89). and install retainer on case (Fig. 87). Then install and tighten lock plate set bolt to 38 N m (28 ft.
Page 1426 21 - 32 AX 4/5 MANUAL TRANSMISSION (10) Install lock ball and spring in housing. Then (12) Install shift tower and new gasket on housing (Fig. 93). Tighten tower bolts to 18 N m (13 ft. lbs.) apply sealer to ball plug and install plug (Fig. 91). torque.
Page 1427 AX 15 MANUAL TRANSMISSION 21 - 33 AX 15 MANUAL TRANSMISSION INDEX page page General Information ..... . . 33 Transmission Installation .

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