1993 Jeep Wrangler Service Manual

SERVICE
MANUAL
Jeep e
ELECTRICAL, HEATING-A/C
& EMISSIONS
CHRYSLER
CORPORATION
ELECTRICAL—HEATING—
A/C-EMISSION SYSTEMS
SERVICE MANUAL
1993 CHEROKEE
WRANGLER(YJ)
To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.
^CHRYSLER
^CORPORATION
SERVICE & PARTS DIVISION
NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY A N Y MEANS, ELECTRONIC, ME
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga
tions upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1992 Chrysler Corporation 20M0992

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system
to be serviced. To assist in locating a group title page, use the Group Tab Locator on the following page. The
solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the
group has a contents section that lists major topics within the group.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the.
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
Navigation: Click on the "Index" below, or use the Bookmarks to the left.
GROUP TAB LOCATOR
Introduction
Qm Battery/Starting/Charging
O A Systems Diagnostics
SB Battery/Starter/Generator Service
SO (Option Systems
SEE Instrument Panel & Gauges
SF Audio Systems
H o m s
Stj
SH Vehicle Speed Control
SJ T u r n Signal/Hazard Warning Flasher
SBC Windshield Wipers & Washers
SL L^PS
R e a r
SN Window Defogger
SP Power Door Locks
SH Power Seats
SS Power Windows
ST Power Mirrors
SU Chime/Buzzer Warning Systems
3W Wiring Diagrams
24 Heating And Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)

/
J INTRODUCTION 1
INTRODUCTION
CONTENTS
page page
DESIGNATIONS, LABELS/PLATES, CODES AND SPECIFICATIONS .... 8

DIMENSIONS ......... 1
DESIGNATIONS LABELS/PLATES, CODES AND DIMENSIONS

y
INDEX
page page
Engine and Transmission/Transfer Case Vehicle Designations 1
Identification 3 Vehicle Dimension Data 4
International Vehicle Control and Display Symbols . 4 Vehicle Identification Number (VIN) Plate ....... 2
Major Component Identification ............... 3 Vehicle Load Data ........................ 4
Tire Inflation Pressure Label . . . . . . . . . . . . . . . . . 3 Vehicle Safety Certification Label ............. 1
Vehicle Code Plate 2
VEHICLE DESIGNATIONS
The Vehicle Designation Codes chart lists the vehi
cle description(s) and the corresponding vehicle des
ignation code for each type of Jeep® vehicle (Figs. 1,
2, and 3). The vehicle designation codes are different
from the Vehicle Identification Number (VIN) or
body-type/style codes.
VEHICLE DESIGNATION CODES
VEHICLE D E S C R I P T I O N CODE
CHEROKEE - 2DR/4WD
CHEROKEE - 4DR/4WD
Fig. 1 YJ—Wrangler Multi-Purpose Vehicle (With
CHEROKEE - 2DR/2WD XJ Hard Top)
VEHICLE SAFETY CERTIFICATION LABEL
CHEROKEE - 4DR/2WD A vehicle safety certification label (Fig. 4) is at
tached to each Jeep® vehiclee. The label also lists
the:
WRANGLER - 4WD YJ
• gross vehicle weight rating (GVWR) and the gross
J931N-15 front and rear axle weight ratings (GAWR's) based
on a minimum tire rim size and a maximum cold tire
inflation pressure;
• month and year of vehicle manufacture;
• vehicle identification number (VIN);
• type of vehicle and
• month, day and hour (MDH) of final assembly.
The label is located on the driver's side door edge.
2 INTRODUCTION J
MFriRV CHRYSLER DATE OF MFR GVWR

M F D B Y
CORPORATION
GAWR FRONT WITH TIRES RIMS AT PSI COLD
GAWR REAR WITH TIRES RIMS AT PSI COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
VIN: TYPE: SINGLE DUAL
BAR CODE
J91IN-13
VEHICLE MADE IN 4648503 J9HN-25
Fig. 2 XJ—Cherokee 2-Door Multi-Purpose Vehicle

Fig. 4 Vehicle Safety Certification Label
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The vehicle identification number (VIN) plate is at
tached to the top left side of the instrument panel at
the base of the windshield. Each VIN contains 17 al
pha-numerical characters. Refer to the decoding
chart to determine the actual identification of a
Jeep® vehicle.
VEHICLE CODE PLATE

A metal vehicle code plate is attached to the left
(driver) side of the dash panel in the engine compart
ment (Fig. 5). There can be a maximum of seven
rows of vehicle information imprinted on the plate.
J9223-15 The information should be read from left to right,

VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country Vehicle Line Engine Sequential

Type P = 2.5 Liter 1-4 Serial Number
1 - U.S. J = Cherokee - 4 W D S = 4.0 Liter 1-6 S i x Digit Numbers
4 - MPV T = Cherokee - 2WD
6 = Incomplete Y = Wrangler - 4 W D
J 0OO001
/
Make
J = Jeep
GVWR
E = 3001-4000 1
Series
- S (YJ)
I
Check Digit
Number or Letter
1993
Model
\ Plant Location
L = Toledo #1
F = 4001-5000 2 = Base Year P = Toledo #2
G = 5001-6000 4 =• Sahara
5 =s Laredo Body
6 = Renegade 7 = 2-Dr. Wagon
8 = 4-Dr. Wagon
9 m 2-Dr. Open Body
J931N-14
INTRODUCTION 3
starting with line 1 at the bottom of the plate up The last nine positions of row 7 will contain a
through line 7 (as applicable) at the top of the code 2-digit code, when applicable, and a 6-digit gateline
plate. serial number (same as the last 6 numbers of the
PRIMARY SECONDARY V I N Y L ROOF
VIN).
PAINT PAINT CODE The last code imprinted on a vehicle code plate will
be followed by the imprinted word END. When two
vehicle code plates are required, the last available
VEHICLE
spaces on the first plate will be imprinted with the
VEHICLE MODEL letters CTD (for continued).
ORDER- -NUMBER
NUMBER
When a second vehicle code plate is necessary, the
(3) XXX )XXX)OOX XXX xxxxxx ENGINE first four spaces on each row will not be used because
PAINT- -CODE of the plate overlap.
PROCEDURE (2) 300C XXXX XX30C XXXX )00C
-INTERIOR
0) XXX X xxxxxxxxxxxxxxxxx TRIM CODE ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
T R A N S M I S S I O N I VEHICLE IDENTIFICATION When required, refer to Group 9—Engines for all
CODE J NUMBER
engine identification data. Refer to Group 21—Trans
M A R K E T U-C-B-M
CODE 90IN-3 missions for all transmission/transfer case identifica
tion data,
Fig. 5 Vehicle Code Plate
Refer to the decoding chart to decode lines 1 up MAJOR COMPONENT IDENTIFICATION
through 3. When required, refer to the applicable service in
formation group for major component identification
VEHICLE CODE DECODING data.
Line # 1 Digit 1-3 Transmission Sales Code TIRE INFLATION PRESSURE LABEL
Digit 4 Open Space The tire inflation pressures label is located on the
Digit 5 Market Code - U-C-B-M
Digit 6 Open Space glove box door inside panel (Fig. 6). The tires should
Digit 7-23 Vehicle Identification No. also be inspected for visible wear. Also, inspect the
Line #2 Digit 1-3 Paint Procedure tires for cracks, bulges and other road hazard dam
Digit 4 Open Space age. Refer to Group 22—Tires And Wheels.
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit 20-22 Engine Sales Code
Digit 23 Open Space
Line #3 Digit 1 - 1 2 Vehicle Order Number

Digit 13 Open Space
Digit 1 4 - 1 6 Vinyl Roof Code (Door Combo
Code - Pillette)
Digit 17 Open Space
Digit 1 8 - 2 3 Model
J901N-20
Lines 4 through 7 (if used) on the vehicle code

plate are imprinted on the plate (in sequence) accord
ing to the following:
• 3-character sales code,
• 3-digit numerical code, and
• 6-digit SEC code.
If there is not enough space left in the row for all
of the 6-digit SEC code (if used):
• the unused space will remain blank, and J891N-3
• the code will be listed in the next row.
Fig. 6 Tire Inflation Pressures Label—Typical
4 INTRODUCTION J
VEHICLE DIMENSION DATA • the cargo weight, and
The vehicle dimension data charts list the exterior • the passenger weight for each Jeep® type/body
and interior dimensions for each type of Jeep® vehi style.
cle.
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
VEHICLE LOAD DATA SYMBOLS
The Vehicle Load Data chart lists the following in Most of the graphic symbols illustrated in the fol
formation:
lowing chart are used to identify various instrument
• the gross vehicle weight rating (GVWR),
controls and displays.
• the gross axle weight ratings (GAWR),
VEHICLE EXTERIOR DIMENSION DATA
TRACK OVERALL
MODEL NAME MODEL RASE FRONT REAR LENGTH WIDTH HEIGHT
cm/in cm/in cm/in
Cherokee 6-in Wheels XJ 257.6 144.8 144.8 420.0 179.1 161.0

2 DR-2WD 101.4 58.0 58.0 165.3 70.5 63.4
7-in Wheels 257.6 144.8 420.0 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Cherokee
4 DR-2WD
Cherokee
6-in Wheels
7-in Wheels
6-in Wheels
XJ
XJ
257.6
101.4
257.6
101.4
257.6
144.8
57.0
147.3
58.0
144.8
144.8
57.0
147.3
58.0
144.8
420.0
165.3
420.0
165.3
420.0
179.1
70.5
179.1
70.5
179.1
161.0
63.4
161.0
63.4
161.0
1
I
2 DR-4WD 101.4 57.0 57.0 165.3 70.5 63.4
7-in Wheels 257.6 147.3 147.3 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4

4 DR-4WD 101.4 57.0 57.0 165.3 70.5 63.4
Is
7-in Wheels 257.6 147.3 147.3 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Wrangler YJ 237.2 147.3 147.3 387.6 167.7 176.5

2 DR-4WD 93.4 58.0 58.0 152.6 66.0 69.5
VEHICLE INTERIOR DIMENSION DATA s

HEAD LEG SHOULDER HIP
VEHICLE MODEL FRONT REAR FRONT REAR FRONT REAR FRONT REAR
cm/in cm/in cm/in cm/in
Cherokee XJ 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0

38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5 o
Wrangler YJ 102.1 102.9 100.1 88.9 134.8 143.0 134.8 91.4 O
(Hardtop) 40.2 40.5 39.4 35.0 53.1 56.3 53.1 36.0
J931N-16
€11
6 INTRODUCTION
J
VEHICLE LOAD DATA
1
BODY WHEEL/ PASSENGER CARGO 3
GAWR 4
GAWR*
VEHICLE STYLE TIRE GVWR* W E I G H T (MAX) W E I G H T (MAX) FRONT REAR
XJ 15x6
2WD 72 P195/75R 4550 750 400 2500 2606
XJ 15x6
2WD 74 P19575R 4600 750 400 2500 2606
XJ 15x6
4WD 72 P195/75R 4850 750 400 2500 2606
XJ 15x6
4WD 74 P195/75R 4900 750 400 2500 2606
72
XJ W/TRAILER 15x7
2WD P215/75R 4550 750 400 2500 2700
TOW PACKAGE
74
XJ W/TRAILER 15x7
2WD P215/75R 4600 750 400 2500 2700
TOW PACKAGE
XJ 72
W/TRAILER 15x7
4WD P215/75R 4850 750 400 2500 2700
TOW PACKAGE
74
XJ W/TRAILER 15x7
4WD P215/75R 4900 750 400 2500 2700
TOW PACKAGE
XJ 15x7
4WD BRIARWOOD P215/75R 4900 750 400 2500 2700
ALL EXCEPT
YJ RENEGADE N/A N/A 300 200 N/A N/A
All Weights Listed In Pounds. 2

72 = 2-Door Body 3
Gross Vehicle Weight Rating
74 = 4-Door Body 4
For MJ Vehicles, includes options
Gross Axle Weight Rating
J931N-17
J INTRODUCTION 7
VEHICLE CONTROL AND DISPLAY SYMBOLS
ID -&
HEADUGHTS,
PARKING UGHTS,
A WINDSHIELD
HIGH BEAM FOG LIGHTS PANEL LIGHTS T U R N SIGNAL HAZARD WARNING WASHER
WINDSHIELD
WIPER
WINDSHIELD WIPER
AND WASHER
<9
WINDSCREEN
DEMISTING
AND DEFROSTING
*
VENTILATING FAN
REAR W I N D O W
DEFOGGER
SP
REAR W I N D O W
WIPER
dp
REAR W I N D O W
WASHER
m
FUEL
ENGINE COOLANT
TEMPERATURE
BATTERY CHARGING
4
SEAT BELT
CONDITION ENGINE OIL
(0 (®) 11 i
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN LIGHTER
93IN-9
8 INTRODUCTION
J
SPECIFICATIONS
SPECIFICATION NOTATIONS Various sizes of (Torx) head fasteners are used
All torque specifications listed in this service man as attaching hardware for numerous compo
ual are in both metric system and SAE/English sys nents in Jeep® vehicles.
tem.
BOLT THREAD AND GRADE/CLASS
WARNING: T H E U S E O F I N C O R R E C T ATTACHING IDENTIFICATION
H A R D W A R E CAN R E S U L T IN COMPONENT DAM
AGE AND/OR P E R S O N A L I N J U R Y . THREAD IDENTIFICATION
SAE and metric bolt/nut threads are different. The
During all procedures, it is important to retain the difference is described in the Thread Notation chart.
original attaching hardware. If the hardware is not
reusable, replace new hardware with equivalent GRADE/CLASS IDENTIFICATION
specifications. The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
METRIC SYSTEM NOTATION the bolt strength. The grade identification is deter
The following conversion chart will assist in con
mined by the line marks on the top of each bolt head
verting SAE/English units to equivalent metric
(Fig. 7). The actual bolt strength grade corresponds
units.
to the number of line marks plus 2. For example:
TORQUE SPECIFICATIONS • a grade 2 bolt has no line marks on top of the bolt
head;
TORQUE CHARTS • a grade 5 bolt has 3 line marks on top of the bolt
If applicable, torque chart(s) for screws, bolts and head;
nuts is/are provided at the end of each service infor • a grade 7 bolt has 5 line marks on top of the bolt
mation group. Refer to the Standard Torque Specifi head; and
cations chart and the bolt grade/class identification • a grade 8 bolt has 6 line marks on top of the bolt
illustrations (Figs. 7 and 8). head.
It is important to be aware that the torque values The most commonly used metric bolt strength
listed in the chart are based on clean and dry bolt classes are 9.8 and 12.9. The metric strength class
threads. Reduce the applicable listed torque value by
identification number is imprinted on the head of the
10 percent when the bolt threads are lubricated with
bolt (Fig. 8). The higher the class number, the
engine oil and by 20 percent if new, plated bolts are
greater the bolt strength. Some metric-dimension
being tightened.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Get

in-lbs x 0.11298 = Newton-Meters (N»m) N-m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (N*m) N-m x 0.7376 = ft-lbs
Inches H g (60°F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches H g

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters (M) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

Feet/Sec. x 0.3048 = Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 ~ = mph
COMMON METRIC EQUIVALENTS
1 Inch = 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard 0.8 Cubic Meter
1 Mile = 1 . 6 Kilometers
J91IN-1
STANDARD TORQUE VALUES
SAE CLASSIFICATION
BOLT TORQUE GRADE5 GRADE 8

GRADE 5 GRADE 8
BOLT
SIZE Nfti fft-Ibi N*m fft-lbs
(In-lbs) (In-lbs)
MARKINGS F O U N D
O N T O P O F BOLT
f<t>
1/4-20 11 (95) 14 (125)
H E A D INDICATE
1/4-28 11 (95) 17 (150)
GRADE
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25 120° 60°
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 no
9/16-12 142 105 183 135
9/16-18 156 115 203 150
5/8-11 203 150 264 195 (SAE) B O L T S - I D E N T I F I C A T I O N M A R K S C O R R E S P O N D
5/8-18 217 160 285 210 T O BOLT STRENGTH—INCREASING NUMBERS
3/4-16 237 175 305 225 R E P R E S E N T INCREASING S T R E N G T H .
J89IN-11
J89IN-9
Fig. 7 SAE Bolt Grade Identification
THREAD NOTATION-SAE AND METRIC
INCH METRIC
5/16-18 M8 X 1.25
THREAD NUMBER THREAD DISTANCE

MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER I N T H R E A D S I N METRIC B O L T S - I D E N T I F I C A T I O N CLASS N U M B E R S
I N INCHES PER INCH MILLIMETERS MILLIMETERS C O R R E S P O N D T O B O L T S T R E N G T H — INCREASING N U M B E R S
R E P R E S E N T INCREASING S T R E N G T H . J89IN-10
PR606B
Fig. 8 Metric Bolt Class Identification
nuts are also imprinted with a single-digit strength
class identification number on the nut face.
10 INTRODUCTION J
TORQUE CONVERSION
in-lbs to N » m N » m to in-lbs
i n - lb N«m in-lb in-lb N«m in-lb N«m in-lb N®m N»m in-lb N®m in-lb N»m in-lb N®m in-lb
4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2

2 .22m42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702
74.3494 109.7539 16.4
.4 4.4 38.9449 8.4 12.4
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292 3.5m 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107
8 .8 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8
.9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 7.0809
1 5 44.2556 9 79.6601 13 115.0646 17
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071 8.8511
12 1.2 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2
1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 10.6213
14 1.4 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4
1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 12.3916
16 1.6 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6
1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 14.1618
1.8 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110 15.9320
2 6 53.1067 10 88.5112 14 123.9157 18
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 17.7022
2.2 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 19.4725
127.4562
24 184 2.4 6.4 56.6472 10.4 92.0517 14.4 19
2.7116 64 7.2309 104 11.7502 144 16.2696 20.7889 21.2427
2.6 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148 23.0129
2.8 6.8 60.1876 10.8 95.5921 14.8 130.9966 20
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408 24.7831
3 7 61.9579 11 97.3624 15 132.7669 20,5
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 26.5534
3.2 7.2 63.7281 11.2 99.1326 15.2 134.5371 21
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 28.3236
3.4 7.4 65.4983 11.4 100.9028 15.4 136.3073 22
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 30.0938
3.6 7.6 67.2685 11.6 102.6730 15.6 138.0775 23
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 31.8640
3.8 7.8 69.0388 11.8 104.4433 15.8 139.8478 24
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 33.6342
4 8 70.8090 12 106.2135 16 141.6180 25
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 35.4045
ft-lbs to N * m N * m to ft-lbs
ft-lb N®m ft-lb N®m ft-lb N®m ft-lb N«m ft-lb N®m N®m ft-lb N«m ft-lb N®m ft-lb N»m ft-lb N®m ft-lb
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.72m 82 60.40)1
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.484) 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.14)5 69 50.6918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.02% 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3m 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6m 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.0)10 36 26.5522 56 41.3035 76 56.0547 96 70.0)60
17 23.0489 37 50.1653 57 77.2816 77 104.39O) 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7922 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 57.5298 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.76^ 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562
in. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .024)2 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 .02441 .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .030)7
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .02598 .86 .03386
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .0374)
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .0060) .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 .00)71 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 .99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 1
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS I
page page
BATTERY TEST PROCEDURES . . . . . . . . . . . . . 2 GENERATOR T E S T PROCEDURES ON

ENGINE STARTER MOTOR TEST PROCEDURES VEHICLE 1S
ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8 IGNITION OFF DRAW (IOD) ...... 14
GENERAL INFORMATION
The Battery, Starting, and Charging Systems oper
ate with one another, and therefore, must be thor MALFUNCTION
INDICATOR
oughly tested as a complete system. In order for the LAMP
vehicle to start and charge properly, it must have a
battery that will perform to specifications. The
starter motor, generator, wiring, and electronics also
DIAGNOSTIC SCAN
must perform within specifications. Group 8A will TOOL
cover Starting (Fig, 1) and Charging (Fig. 2) System
diagnostic procedures. These procedures include the
most basic conventional methods to On Board Diag
nostics (OBD) built into the Powertrain Control Mod
ule (PCM). Use of an ammeter, volt/ohmmeter,
battery charger, carbon pile rheostat (load tester),
and 12 volt test light will be required.
POWERTRAIN CONTROL
MODULE
NEGATIVE
BATTERY
7
POSITIVE
BATTERY
CABLE
CABLE
A. BATTERY
GENERATOR
BATTERY
Fig. 2 Charging System Components

J938A-23
All OBD sensing systems are monitored by the

J918A-11
PCM. The PCM will store in memory any detectable
Fig. 1 Starting System Components (Typical) failure in the monitored circuits. Refer to Using On-
Board Diagnostic System in this group for more in
formation.
8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS J
BATTERY TEST PROCEDURES
INDEX
page page
Battery Charging 4 Battery Testing General Information 2
Battery Diagnostics Chart 7 General Information 2
Battery Load Test 3 Hydrometer Test . 2
Battery Open Circuit Voltage Test 3 Specifications 8
GENERAL INFORMATION Completely discharged batteries may take sev

The battery stores, stabilizes, and produces electri eral hours to accept a charge. See Charging A
cal current. A battery must be able to accept a Completely Discharged Battery.
charge and produce high-amperage current output A battery that has been fully charged but does not
over an extended period. A chemical reaction be pass the battery load test is defective.
tween the sulfuric acid solution (electrolyte) and the A battery is fully charged when:
lead +/-plates in each cell of the battery. As the bat • all cells are gassing freely during charging
tery discharges, the plates collect the acid from the • 3 corrected specific gravity tests, taken at 1-hour
electrolyte. When the charging system charges the intervals, indicate no increase in specific gravity.
battery, water is converted to sulfuric acid in the
battery. The amount of acid (specific gravity) in the CAUSES OF BATTERY DISCHARGING
electrolyte can be measured with a hydrometer. The It is normal to have a 5 to 20 milliamperes Ignition
battery is vented to release gases that are created Off Draw (IOD) from the battery with all lamps OFF.
when the battery is being charged. The battery top, Electronic features or accessories that have a mem
posts, and terminals should be cleaned when other ory circuit cause IOD. When a vehicle is not used for
underhood maintenance is performed. 20 days or more, remove IOD fuse in the Power Dis
tribution Center to reduce battery discharging.
WARNING: DO NOT A T T E M P T T O A S S I S T B O O S T ,
CHARGE, O R T E S T B A T T E R Y W H E N E L E C T R O ABNORMAL BATTERY DISCHARGING
L Y T E L E V E L I S BELOW T H E T O P OF T H E P L A T E S . (1) Corroded battery posts and terminals.
P E R S O N A L I N J U R Y MAY OCCUR. (2) Loose or worn generator drive belt.
(3) Electrical loads that exceed the output of the
When the electrolyte level is below the top of the
charging system due to equipment or accessories in
plates distilled water should be added. The battery
must be completely charged. The top, posts, and ter stalled after delivery.
minals should be properly cleaned before diagnostic (4) Slow driving speeds (heavy traffic conditions)
procedures are performed, see Group 8B - Battery/ or prolonged idling with high-amperage draw sys
Starter Service, for additional information. tems in use.
(5) Defective circuit or component causing excess
BATTERY TESTING GENERAL INFORMATION IOD. Refer to Ignition Off Draw in this Group.
Before testing a battery, clean the top of the (6) Defective charging system.
battery case, posts and cable terminals. (7) Defective battery.
The specific gravity is a ratio of the density of the
electrolyte and the density of pure water. The elec HYDROMETER TEST
trolyte is composed of sulfuric acid and water. Acid Before performing a hydrometer test, remove
comprises approximately 35% by weight or 24% by the battery caps and check the electrolyte level.
volume. Add distilled water and charge as required.
The condition of a battery may be determined from Before testing, visually inspect the battery for any
the results of 2 tests: damage (cracked case or cover, loose post, etc.) that
• state of charge (hydrometer test) would cause the battery to be defective. To use the
• ability to supply current (battery load test). hydrometer correctly, hold it with the top surface of
Perform the hydrometer test first. If the specific the electrolyte at eye level. Refer to manufacturers
gravity is less than 1.225, (with battery at room tem instructions for correct use of hydrometer.
perature) the battery must be charged before pro Remove only enough electrolyte from the battery to
ceeding with further testing. A battery that will not keep the float off the bottom of the hydrometer bar
accept a charge is defective and further testing is not rel with pressure on the bulb released. Exercise care
necessary. when inserting the tip of the hydrometer into a cell
J BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3
to avoid damage to the separators. Damaged separa Battery/Starter Service for instructions. To test bat
tors can cause premature battery failure. tery no load voltage, perform the following operation:
Hydrometer floats are generally calibrated to show (1) Before measuring open circuit voltage, the sur
the specific gravity correctly only at one fixed tem face charge must be removed from plates. Turn head
perature, 80°F (26.6°C). When testing the specific lights on for 15 seconds then allow up to 5 minutes
gravity at any other temperature, a correction factor for voltage to stablize.
is required. (2) Remove both battery cables, negative first.
The correction factor is approximately a specific (3) Using a voltmeter connected to the battery
gravity value of 0.004, referred to as 4 points of spe posts, see instructions provided with voltmeter, mea
cific gravity. For each 10°F above 80°F (5.5°C above sure open circuit voltage (Fig. 3).
26.6°C), add 4 points. For each 10°F below 80°F This voltage reading will indicate state of charge,
(5.5°C below 26.6°C), subtract 4 points. Always cor but will not reveal cranking capacity. Refer to Bat
rect the specific gravity for temperature variation. tery Open Circuit Voltage chart.
Test the specific gravity of the electrolyte in each BATTERY OPEN CIRCUIT VOLTAGE
battery cell.
Example: A battery is tested at 10°F (-12.2°C) and
has a specific gravity of 1.240. Determine the actual
Open Circuit Volts Percent Charge
specific gravity as follows:
• Determine the number of degrees above or below
11.7 volts o r less 0%
80°F.
80°F - 10°F = 70°F 12.0 25%
• Divide the result above by 10. 12.2 50%

70°F/10 = 7 12.4 75%
• Multiply the result from the previous step by the 12.6 o r more 100%
temperature correction factor (0.004).
928A-3
7 x 0.004 = 0.028
• The temperature at testing was below 80°F, there
fore the temperature correction is subtracted.
1.240 - 0.028 = 1.212
The corrected specific gravity is 1.212.
The fully charged battery should have a tempera
ture corrected specific gravity of 1.250 to 1.265.
If the specific gravity of all cells is above 1.235,
and cell variation is more than 50 points (0.050), it is
an indication that the battery is unserviceable.
If the specific gravity of one or more cells is less
than 1.235, charge the battery at a rate of approxi
mately 5 amperes. Continue charging until 3 consec
utive specific gravity tests, taken at 1 hour intervals,
are constant. 898A-7
If the cell specific gravity variation is more than 50
Fig. 3 Testing Open Circuit Voltage
points (0.050) after the charge period, replace the
battery. BATTERY LOAD T E S T
When the specific gravity of all cells is above 1.235
and variation between cells is less than 50 points WARNING: IF BATTERY SHOWS SIGNS OF FREEZ
(0.050), the battery may be tested under heavy load. ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO
LYTE LEVEL, DO NOT TEST. ACID BURNS OR
BATTERY OPEN CIRCUIT VOLTAGE TEST EXPLOSIVE CONDITION MAY RESULT.
A battery voltage (no load) test will show state of
charge of a battery that will pass the Battery Load A battery load test will verify the cranking ability
Test described in this section. Before proceeding based on the cold crank rating of the battery.
with this test or Battery Load Test, completely Before performing battery load test, the bat
charge battery as described in Battery Charging tery must be FULLY CHARGED.
in this section, Before performing the battery load test, the
If a battery has a no load voltage reading of 12.4 battery must have a specific gravity above 1.225.
volts or greater and will not endure a load test, it is (1) Remove both battery cables, negative first. Bat
defective and should be replaced. Refer to Group 8B - tery top and posts should be clean.
8A - 4 BATORY/STARTING/CHARGING SYSTEMS DIAGNOSTICS J
(2) Connect a suitable Volt-Ammeter-Load tester

(Fig. 4) to the battery posts (Fig. 5). Refer to operat
ing instructions provided with the tester being used.
Check the open circuit voltage (no load) of the bat
tery. Voltage should be equal to or greater than 12.4
volts (Fig. 5).
898A10
Fig. 6 Remove Surface Charge from Battery
898A-11
Fig. 7 Load 50% Cold Crank Rating Note Voltage

(7) If the voltmeter reading fell below 9.6 volts,
with the battery temperature at a minimum of 70°F
(21°C), replace the battery.
J908A-12
Fig. 5 Volt-Ammeter-Load Tester Connections LOAD TEST TEMPERATURE

Minimum Voltage Temperature
(3) Rotate the load control knob (carbon pile rheo
stat) to apply a 300 amp load for 15 seconds then re F C°
turn the control knob to off (Fig. 6). This will remove 9.6 70 and above 21 arid above
the surface charge from the battery. 9.5 60 16
(4) Allow the battery to stabilize to open circuit 9.4 50 10
voltage (may take up to 5 minutes). 40 4
9.3
(5) Rotate the load control knob to maintain a load
9.1 30 -1
(50% of cold crank rating—see Specifications) for a
minimum of 15 seconds (Fig. 7). After 15 seconds, 8.9 20 -7
record the (loaded) voltage reading and return the 8.7 10 -12
load control to off. 8.5 0 -18
(6) Voltage drop will vary according to battery J908A-4
temperature at the time of the load test. Battery
temperature can be estimated by the ambient tem BATTERY CHARGING
perature over the past several hours. If the battery A battery is completely charged when it has:
has been charged, boosted, or loaded a few minutes • an open circuit voltage of 12.4 volts or more.
prior to test, the battery would be somewhat warmer. • has enough cranking capacity (minimum 9.6 volts
Refer to Load Test Temperature chart for proper when loaded for 15 seconds to 50% of cold cranking
loaded voltage reading. amperage rating at 21°C/70°F).
J 3ATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 5
An open circuit voltage of 12.4 volts or greater, in BATTERY CHARGING TIME TABLE
dicates it is charged enough for further testing and
possibly returned to use. Charging Amperage 5 Amps 10 Amps 20 Amps
WARNING: DO N O T C H A R G E A B A T T E R Y T H A T Open Circuit Voltage Hours Charging at 21°C (70°F)
H A S L O W E L E C T R O L Y T E L E V E L . B A T T E R Y MAY 12.25 to 12.39 6Hrs. 3Hrs. 1 5Hr
A R K I N T E R N A L L Y AND E X P L O D E . 12.00to12.24 8Hrs. 4 Hrs. 2 Hrs.
11.95to12.09 12Hrs. 6Hrs. 3 Hrs.
10.00to11.95 14 Hrs. 7 Hrs. 3.5 Hrs.
WARNING: E X P L O S I V E G A S E S FORM OVER B A T
T E R Y , DO NOT S M O K E , U S E F L A M E , O R C R E A T E 10.00to0 See Charging Completely
Discharged Battery
S P A R K S NEAR B A T T E R Y .
928A-19
WARNING: DO NOT A S S I S T B O O S T OR C H A R G E A (1) Size of Battery— A completely discharged
F R O Z E N B A T T E R Y , CASING MAY F R A C T U R E . large heavy-duty battery requires more than twice
the recharging time as a completely discharged small
capacity battery.
WARNING: POISON, C A U S E S S E V E R E B U R N S .
B A T T E R Y CONTAINS S U L F U R I C ACID, AVOID CON WARNING: N E V E R E X C E E D 20 A M P S W H E N
T A C T W I T H S K I N , E Y E S , OR CLOTHING. IN E V E N T CHARGING A COLD (-1°C/30°F) B A T T E R Y , P E R
OF CONTACT, F L U S H W I T H W A T E R AND C A L L S O N A L I N J U R Y MAY R E S U L T .
PHYSICIAN I M M E D I A T E L Y . K E E P O U T O F R E A C H
OF C H I L D R E N . (2) Temperature — A longer time will be needed
to charge a battery at -18°C (0°F) than at 27°C
(80°F). When a fast charger is connected to a cold
CAUTION: Disconnect the vehicle's battery negative
battery, current accepted by battery will be very low
cable before charging battery to avoid damage to
at first. Then, in time, the battery will accept a
electrical systems. Do not exceed 16.0 volts while
higher rate as battery warms.
charging battery.
(3) Charger Capacity— A charger, that supplies
Battery electrolyte will bubble inside case while only 5 amperes, will require a much longer period for
being charged properly. If the electrolyte boils vio charging than a charger that supplies 20 amperes or
lently or is discharged from the vent holes while more.
charging, immediately reduce charging rate or turn (4) State Of Charge— A completely discharged
off charger and evaluate battery condition. battery requires more charging time than a partially
Battery should not be hot to touch. charged battery. Electrolyte is nearly pure water in a
If the battery feels hot to the touch, turn off completely discharged battery. At first the charging
charger and let cool before restarting. current amperage will be low. As the battery charges
Some battery chargers are equipped with polarity the specific gravity of the electrolyte will rise slowly.
( + to +/- to -) sensing devices to protect the charger CHARGING COMPLETELY DISCHARGED
or battery from being damaged if improperly con BATTERY
nected. If the battery state of charge is too low for The following procedure should be used to recharge
the polarity sensor to detect, the sensor must be by a completely discharged battery. Unless procedure is
passed for charger to operate. Refer to operating in properly followed, a good battery may be needlessly
structions provided with battery charger being used. replaced.
After the battery has been charged to 12.4 volts or (1) Measure voltage at battery posts with a volt
greater, perform a load test to determine cranking meter, accurate to 1/10 volt (Fig. 8). If below 10
capacity. If the battery will endure a load test, re volts, then charge current will be low and it could
turn the battery to use. If battery will not endure a take some time before it accepts a current greater
load test, it must be replaced. Clean and inspect bat than a few milliamperes. Such low current may not
tery hold downs, tray, terminals, posts, and top be be detectable on ammeters built into many chargers.
fore completing service, see Group 8B - Battery/ (2) Connect charger leads. Some chargers feature
Starter/Generator Service. polarity protection circuitry that prevents operation
unless charger is connected to battery posts correctly.
CHARGING TIME REQUIRED A completely discharged battery may not have
The time required to charge a battery will vary de enough voltage to activate this circuitry, even
pending upon the following factors: though leads are connected properly, making it ap-
(3) Battery chargers vary in the amount of voltage

and current they provide. For time required for bat
tery to accept measurable charger current at various
voltages, refer to Charge Rate chart. If charge cur
rent is still not measurable at end of charging times,
the battery should be replaced. If charge current is
measurable during charging time, the battery may
be good and charging should be completed in the nor
mal manner.
CHARGE RATE
898A-12
Voltage Hours
Fig. 8 Voltmeter Accurate to 1/10 Volt Connected
pear that battery will not accept charging current. 16.0 volts maximum up to 4 hrs.
Refer to instructions provided with battery charger
being used. 14.0 to 15.9 volts up to 8 hrs.
13.9 volts or less up to 16 hrs.
J928A-6
BATTERY DIAGNOSTICS CHART
r STARTER WON'T CRANK VISUAL INSPECTION

Jr CHECK FOR OBVIOUS D A M A G E SUCH A S CRACKED O R
BROKEN CASE T H A T S H O W S LOSS O F ELECTROLYTE,
BROKEN/CRACKED
T E R M I N A L D A M A G E , LOOSE O R CORRODED
F. C. = 1
CONNECTIONS, CLEAN A N D T I G H T E N CONNECTORS
REPLACE B A T T E R Y *
STARTER STILL WON'T CRANK

PROCEED T O S T A R T E R T E S T NO OBVIOUS DAMAGE
PROCEDURES O N VEHICLE IN T H I S G R O U P
PERFORM B A T T E R Y V O L T A G E T E S T O P E N CIRCUIT ( B A T T E R Y V O L T A G E TEST)

1 . T U R N H E A D L A M P S O N F O R 15 SECONDS
2. T U R N H E A D L A M P S O F F FOR 2 M I N U T E S T O A L L O W
BATTERY VOLTAGE T O STABILIZE
3. REMOVE N E G A T I V E , T H E N POSITIVE CABLE.
POSSIBLE CAUSE—IOD-REFER
T O IGNITION O F F D R A W SECTION
STARTER STILL WON'T CRANK

E L I M I N A T E EXCESS IOD PROCEED T O S T A R T E R T E S T
N O EXCESS IOD F O U N D
F. C. = 2 PROCEDURES O N VEHICLE IN
THIS GROUP
G R E E N BALL S H O W I N G A N D
•CHARGE BATTERY—REFER CHARGE O P E N CIRCUIT V O L T A G E
T O CHARGING B A T T E R Y ACCEPTED A B O V E 12.40 V O L T S * *
W O N ' T ACCEPT C H A R G E
F. C. = 3
1 . N O G R E E N BALL S H O W I N G
2. O P E N CIRCUIT V O L T A G E B E L O W 12.40
V O L T S . SEE CHARGING COMPLETELY
DISCHARGED B A T T E R Y L O A D T E S T V O L T A G E CHARGE
MINIMUM
ESTIMATED REQUIRED
LOAD TEST ELECTROLYTE VOLTAGE
DISCHARGE B A T T E R Y A T 300 A M P E R E S F O R 15 S E C O N D S . A L L O W B A T T E R Y TEMPERATURE UNDER
15 SEC. LOAD
T O RECOVER F O R 15 S E C O N D S . C O N N E C T V O L T M E T E R A N D A M P E R E L O A D
E Q U A L T O 1/2 T H E COLD C R A N K I N G A M P E R E R A T I N G O F T H E B A T T E R Y F O R 70° F (21°C)& A B O V E 9.6
15 S E C O N D S . O B S E R V E V O L T A G E A T 15 S E C O N D S W I T H L O A D O N . 60° F (16° C) 9.5
NOTE: ESTIMATE TEMPERATURE OF BATTERY. 50°F ( 1 6 C) s
9.4
REFER T O L O A D T E S T V O L T A G E CHART. 40° F (4°C) 9.3
30°F (~1°C) 9.1
±
VOLTAGE A T O R ABOVE
9.6 V O L T S A T R O O M
VOLTAGE BELOW
20°F (~7°C)
10°F(-12°C)
0°F(~18°C)
8.9
8.7
8.5
9.6 V O L T S A T R O O M
(70 DEG. F) T E M P . (70 D E G . F) T E M P . V O L T M E T E R M U S T BE ACCURATE
* T O 1/10 V O L T
FAILED L O A D T E S T
PASSED LOAD TEST
F. C. = 4
RETURN BATTERY T O USE
'REPLACE BATTERY F A I L U R E CODE ( F . C ) C H A R T
FAILURE CODE (F.C.) CONDITION
NUMBER
STARTER STILL WON'T CRANK 1 BROKEN/CRACKED
PROCEED T O S T A R T E R T E S T 2 IGNITION OFF DRAW
PROCEDURES O N VEHICLE IN 3 B A T T E R Y W O N T ACCEPT CHARGE
THIS GROUP 4 B A T T E R Y FAILED L O A D T E S T
NOTES: * AFTER CHARGING O R REPLACING A BATTERY.

CHECK T H E V E H I C L E ' S C H A R G I N G S Y S T E M , A N D * * CHECKING O P E N CIRCUIT V O L T A G E W I L L
GLEAN A N D T I G H T E N B A T T E R Y CONNECTORS MONITOR "GREEN B A L L " INDICATION
(REFER T O A P P L I C A B L E S E C T I O N S O F T H I S FOR A L L 6 CELLS. J928A-8
SERVICE M A N U A L ) .
SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS TORQUE SPECIFICATIONS
Ceiii tesenre Vehicle Description Torque

Group Crank C@p@€ftf Engine
Size Series Battery Strap Screw 2 N*m (20 i n . lbs.)
&mm (Min.)
Battery Tray N u t 2 N*m (20 i n . lbs.)
58 430 80 2.5L & 4.0L All
Battery Clamp N u t 2 N*m (20 in. lbs.)
58 500 85 2.5L, 4.0L All J928A-7
J928A-1
ENGINE STARTER MOTOR T E S T P R O C E D U R E S ON V E H I C L E
INDEX
page page
2.5L Starter Motor Noise Diagnosis 12 Starter Feed Circuit Tests - (Voltage Drop Method) . 9
Cold Cranking Test 8 Starter Motor Testing (Out of Vehicle) 12
Starter Control Circuit Tests 10 Starter System Diagnostic Inspections 8
STARTER SYSTEM DIAGNOSTIC INSPECTIONS • switch

Before removing any unit from the starter motor • solenoid
system for repair, perform the following inspections: • relay
e park/neutral position switch
BATTERY INSPECTION
To determine condition of the battery, perform the COLD CRANKING TEST
testing procedure outlined in the Battery Section. (1) Battery must first pass load and voltage drop
tests and be fully charged before proceeding. Refer to
WIRING INSPECTION Battery Test Procedures.
Inspect wiring for damage. Inspect all connections (2) Connect a suitable volt-ampere tester to the
at the starter motor solenoid, park/neutral position battery terminals (Fig. 1), refer to the operating in
switch (if equipped), back-up lamp switch connector, structions provided with the tester being used.
ignition/start switch, and battery (including all (3) Fully engage parking brake, place manual
ground connections). Clean and tighten all connec transmission in NEUTRAL, automatic transmission
tions as required. in PARK.
(4) Verify that all lights and accessories are OFF.
SOLENOID, RELAY AND IGNITION/START (5) Remove coil secondary cable from distributor
SWITCH INSPECTION and connect to ground.
Inspect the solenoid, relay and switch to determine (6) Rotate and hold the ignition switch (key) in the
their condition. Also, if equipped with automatic START position. Note cranking voltage and amper
transmission, inspect condition of the park/neutral age.
position switch. (Testing information can be found in (a) If voltage reads above 9.6 volts and amperage
the following pages). draw reads above specifications, go to Starter Feed
If the following components are in satisfactory con Circuit Tests.
dition (and the engine is known to be functioning (b) If voltage reads 12.5 volts or greater and am-
properly), remove the starter motor and follow proce perate reads 0 to 10 amps, go to Starter Control
dures in the Testing Section. Circuit Tests.
• battery A cold engine will increase starter motor cur
• wiring rent.
STARTING SYSTEM DIAGNOSIS
TEST CONDITIONS
• PLACE GEAR SELECTOR IN PARK OR NEUTRAL AND SET PARK BRAKE OR EQUIVALENT.
• VERIFY BATTERY STATE-OF-CHARGE AND CRANKING CAPACITY, SEE BATTERY SECTION.
• CLEAN BATTERY TOP, POSTS, AND TERMINALS.
• VERIFY ALTERNATOR DRIVE BELT T E N S I O N .
• DISCONNECT AND GROUND COIL CABLE.
SYMPTOM SYMPTOM SYMPTOM SYMPTOM SYMPTOM
STARTER FAILS TO STARTER FAILS TO STARTER ENGAGES, STARTER ENGAGES STARTER DOES NOT
ENGAGE. NO SOUNDS ENGAGE SOLENOID FAILS TO TURN DRIVE CLUTCH DISENGAGE AFTER
OR RELAY CLICKS ENGINE. DOME LIGHT SPINS OUT ENGINE STARTS
DIMS
POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
STARTER CONTROL RESISTANCE TOO RESISTANCE TOO DRIVE CLUTCH FAULTY IGNITION SWITCH
CIRCUIT FAULTY HIGH IN STARTER HIGH IN STARTER FAULTY
FEED CIRCUIT FEED CIRCUIT
BROKEN TEETH
IGNITION SWITCH ON RING GEAR STARTER RELAY
FAULTY STARTER CONTROL STARTER ASSEMBLY FAULTY
CIRCUIT FAULTY FAULTY
STARTER ASSEMBLY
PARK/NEUTRAL FAULTY STARTER ASSEMBLY
POSITION STARTER SOLENOID ENGINE FAULTY
SWITCH FAULTY SEIZED
(AUTO TRANS.)
FAULTY OR STARTER
MISADJUSTED STARTER ASSEMBLY IMPROPERLY
FAULTY MOUNTED
STARTER RELAY REFER TO

FAULTY APPROPRIATE GROUP
AND SECTION OF THIS
MANUAL FOR PROPER
STARTER ASSEMBLY SERVICE AND TEST
FAULTY PROCEDURES FOR THE
COMPONENTS
INVOLVED
J938A-9
STARTER FEED CIRCUIT TESTS - (VOLTAGE DROP

METHOD)
The voltage drop tests will determine if there is ex
cessive resistance in the high current circuit. When
performing these tests, it is important that the volt
meter be connected to the terminals that the cables
are connected to instead of to the cables themselves.
For example, when testing between the battery and
solenoid, touch the voltmeter test probes to the bat
tery post and the solenoid threaded stud. The follow
ing operation will require a voltmeter, accurate to
1/10 of a volt.
Before performing the tests, assure the following
procedures are accomplished:
• remove coil secondary cable from distributor and
Fig. 1 Volt-Amps Tester Connections (Typical) connect to ground
8A - 1 1 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS J
• transmission in NEUTRAL (manual transmission) rect poor contact at battery cable to solenoid connec
or P A R K (automatic transmission) tion. If reading is still above 0.2 volt, replace positive
© parking brake applied battery cable.
• battery is fully charged (refer to Group 8A - Bat (5) Connect the voltmeter to measure between the
tery) battery negative post and the engine block (Fig. 4).
(1) Connect positive lead of the voltmeter to the
battery negative post, and negative lead to the bat VOLTMETER
tery negative cable clamp (Fig. 2). Rotate and hold
the ignition switch (key) in the START position. Ob
serve the voltmeter. If voltage is detected, correct
poor contact between the cable clamp and post.
(2) Connect positive lead of voltmeter to the bat
tery positive post, and negative lead to the battery
cable positive clamp (Fig. 2). Rotate and hold the ig
nition switch (key) in the START position. Observe
the voltmeter. If voltage is detected, correct poor con
tact between the cable clamp and post.
ENGINE v
VOLTMETER GROUNDX BATTERY 5
Fig. 4 Test Ground Circuit Resistance

(6) Rotate and hold the ignition with (key) in the
START position. If voltage reads above 0.2 volt, cor
rect poor contact at ground cable attaching point.
Voltage reading still above 0.2 volt, replace ground
cable.
BATTERY (7) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 5).
STARTER BATTERY
898Ar17 MOTOR
Fig. 2 Test Battery Connection Resistance

(3) Connect a voltmeter to measure between the
battery positive post and the center of the B +
starter solenoid stud (Fig. 3).
VOLTMETER
BATTERY
898A-26
Fig. 5 Test Starter Motor Ground (Typical)

(8) Rotate and hold the ignition switch (key) in the
START position. If voltage reads above 0.2 volt, cor
rect poor starter to engine ground.
If resistance tests detect no feed circuit failures, re
STARTER move the starter motor and go to Bench Testing
MOTOR VOLTMETER 898A-20 Starter Solenoid.
Fig. 3 Test Positive Battery Cable Resistance STARTER CONTROL CIRCUIT TESTS
(Typical) The starter control circuit consists of a starter so
(4) Rotate and hold the ignition with (key) in the lenoid, starter relay, ignition switch, safety neutral
START position. If voltage reads above 0.2 volt, cor switch (automatic transmission), and all their wiring
and connections.
Testing procedures for these components are as fol

lows and should be followed in order as described.
CAUTION: Before performing any test disconnect

distributor connector to prevent engine from start
ing.
SOLENOID TESTING
Refer to Group 8B - Battery Starter Service for
starter removal procedures.
(1) Disconnect field coil wire from field coil termi
nal.
(2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester.
There should be continuity (Fig. 6).
Fig. 6 Continuity Test Between Solenoid Terminal

and Field Coil Terminal
(3) Check for continuity between solenoid terminal
and solenoid housing. There should be continuity
(Fig. 7).
Fig. 7 Continuity Test Between Solenoid Terminal

and Solenoid Case
(4) If there is continuity, solenoid is good. If there
is no continuity in either test, solenoid has an open
circuit and is defective. Replace starter motor.
(5) Install starter as described in Group 8B.
(6) Connect field coil wire to field coil terminal. Fig. 9 Power Distribution Center— YJ
STARTER RELAY OPERATION/TESTING energized position which supplies battery voltage to
The starter relay is in the Power Distribution Cen the operated device.
ter (Figs. 8 and 9). Refer to the underside of the e Terminal No. 86 is connected to the electromagnet
Power Distribution Cover for relay location. and usually connected to a switched power source,
e Terminal No. 85 is connected to the electromagnet
OPERATION and is usually grounded by a switch or ECU.
• Terminal No. 30 is usually connected to battery
voltage and can be switched or B + at all times. TESTING
• Terminal No. 87A is connected to terminal 30 in Remove relay from the Power Distribution Center
the de-energized position. to perform the following tests.
• Terminal No. 87 is connected to terminal 30 in the
8A - 1 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS J
STARTER RELAY CONNECTIONS No rotation and no current flow conditions suggests

one or more of the following:
• Open armature windings (inspect commutator for
IGNITION NOT
badly burned commutator bars after disassembly).
• Broken brush springs, worn brushes, protruding
insulation between commutator bars, or other causes
could prevent good contact between brushes and com
mutator.
GROUND SOLENOID
(85) TERMINAL
• A relay in the de-energized position should have

continuity between terminal 87A and terminal 30.
• Resistance value between terminals 85 and 86
(electromagnet) is 75 ±5 ohms.
• Connect a battery to terminals 85 and 86. There
should be continuity between terminal 30 and 87.
IGNITION SWITCH TEST

After testing starter solenoid and relay and they
check out okay, trouble is probably with ignition
switch or its wiring.
Check all wiring for opens and shorts and connec
tions for being loose or corroded.
PARK/NEUTRAL POSITION SWITCH

Refer to Group 21 - Transmissions for diagnostic
information.
STARTER MOTOR TESTING (OUT OF VEHICLE)

Once a problem has been traced to the starter mo
tor, proceed with the following test procedure.
With the starter motor removed from the engine,
the pinion gear should be tested for freedom of move
ment by turning it on the screw shaft.
The armature should be tested for freedom of rota
tion by prying the pinion gear with a screwdriver to
engage it with the shaft. Tight bearings, a bent ar
mature or drive shaft, or a bent frame will cause the
armature not to rotate freely. If the shafts do not ro
tate freely, the motor should be replaced.
No rotation and high current flow conditions sug
gest one or more of the following:
• Connecting terminal or armature windings shorted
to ground.
• Seized bearings (this should have been determined
by rotating armature by hand).
CONDITION POSSIBLE CAUSE CORRECTION
1. VERY H I G H F R E Q U E N C Y 1 . Excessive distance between pinion gear and 1. Shim starter motor toward flywheel/drive
WHINE BEFORE ENGINE flywheel/drive plate gear. plate.
STARTS; ENGINE STARTS OK.
2. VERY H I G H F R E Q U E N C Y 2. Insufficient distance between starter motor 2. Shim starter motor away from flywheel/drive
WHINE AFTER ENGINE STARTS pinion gear and flywheel/drive plate runout plate. Inspect flywheel/drive plate for
W I T H I G N I T I O N KEY R E L E A S E D . can cause noise to be intermittent. damage; bent, unusual wear, and excessive
ENGINE STARTS OK. runout. Replace flywheel/drive plate as
necessary.
3. A L O U D " W H O O P " A F T E R 3. Most probably cause is defective overrunning 3. Replace starter.

ENGINE STARTS WHILE clutch.
S T A R T E R M O T O R IS E N G A G E D .
4. A " R U M B L E , " " G R O W L , " O R 4. Most probable cause is bent o r unbalanced 4. Replace starter motor armature.
" K N O C K " AS STARTER M O T O R starter motor armature.
COASTS T O S T O P AFTER
ENGINE STARTS.
N O T E : A high frequency whine during cranking is normal for this starter motor.
J928A-9
2.5L STARTER MOTOR NOISE DIAGNOSIS

If the complaint is similar to Conditions No. 1 and
No. 2, correction can be achieved by proper "shim
ming" according to the following procedures:
STARTER
• Disconnect the battery negative cable (to prevent MOTOR
inadvertent starting of engine). SHIM
Two shim thicknesses are available. One is
0.381 mm (0.015 in.) and the other is 1.143 mm
(0.045 in.).
If the complaint is similar to Condition No. 1, the
starter motor must be moved toward the flywheel/
driveplate using thinner shims (Fig. 10).
This is generally a condition that causes bro
ken flywheel/driveplate ring gear teeth or bro
ken starter motor housings. 1
W « J908C-1
If the complaint is similar to Condition No. 2, the
starter motor must be moved away from the fly Fig. 10 Starter Motor Shimming
wheel/driveplate. This is done by installing shim(s)
across both mounting pads. More than one shim may
be required.
IGNITION OFF D R A W (IOD)

GENERAL INFORMATION The test light may light brightly for up to 3 min
Ignition off draw refers to power being drained utes or may not light at all (depending on the- elec
from the battery with the ignition turned off. A nor trical equipment). The term brightly being used
mal vehicle electrical system will draw from 5 to 20 throughout the following tests, implies the bright
milliamps. This is with the ignition in the OFF posi ness of the test light will be the same as if it were
tion, and all non-ignition controlled circuits in proper connected across the battery.
working order. A vehicle that has not been operated The test light must be securely clamped to the neg
for approximately 20 days, may discharge the battery ative cable and battery terminal. If the test light be
to an inadequate level. Battery drain should not ex comes disconnected during any of the IOD test, the
ceed approximately 20 MA (20 milliamps = 0.020 electronic timer function will be activated and all
amps). tests must be repeated.
The 20 MA are needed to supply PCM memory, If the ammeter circuit is broken the Security
digital clock memory, and ETR (electronically tuned alarm module will turn on parking lamps.
radio) memory.
(5) After 3 minutes, the test light should turn OFF
Excessive battery drain is caused by items left
or be DIMLY lit (depending on the electrical equip
turned on, internally shorted generator, or intermit
ment). If the test light remains brightly lit do not
tent short in wiring.
disconnect it. Remove each fuse or circuit breaker
If the IOD is over 20 milliamperes, the defect must
(refer to Group 8 - Wiring Diagrams) until test light
be found and corrected before replacing a battery. In
most cases the battery can be charged and returned is either OFF or DIMLY lit. This will eliminate the
to service. higher amperage draw.
If test light is still bright after disconnecting each
TEST PROCEDURE fuse and circuit breaker, disconnect the wiring har
Testing for higher amperage IOD must be per ness from the generator. Refer to Generator Testing
formed first to prevent damage to most milliamp in this group. Do not disconnect the test light.
meters. After higher amperage IOD has been corrected, low
(1) Verify that all electrical accessories are OFF. amperage IOD may be checked.
Turn off all lights, remove ignition key, and close all It is now safe to install milliamp meter to check for
doors. If the vehicle is equipped with electronic acces low amperage IOD.
sories (illuminated entry, or high line radio), allow (6) With test light still connected securely clamp
the systems to automatically shut off (time out), up an ammeter between battery negative terminal and
to 3 minutes. negative battery cable.
(2) After determining that the underhood lamp is Do not open any doors or turn on any electri
operating properly then disconnect bulb. cal accessories with the test light disconnected
(3) Disconnect negative cable from battery. or the meter may be damaged.
(4) Connect a typical 12 volt test light (low watt (7) Disconnect test light. The current draw should
age bulb) between the negative cable clamp and the not exceed 0.020 amp. If it exceeds 0.020 milliamps
battery negative terminal. If equipped with security isolate each circuit by removing circuit breakers and
alarm, cycle the key in the door to turn off the flash fuses. The meter reading drops once the high current
ing lights. Make sure that the doors remain closed so problem is found. Repair this section of the circuit,
that illuminated entry is not activated. whether it is a wiring short or component failure.
J
GENERATOR TEST PROCEDURES ON VEHICLE
INDEX
page page
Diagnostic Procedures 15 Operational Check with Battery Indicator
General Information 15 (Base Cluster Only) 15
How to Use Malfunction Indicator (Check Engine) Operational Check with Voltmeter 15
Lamp for Diagnostic Trouble Codes 18 Using On-Board Diagnostic System . . . . . . . . . . . 18
GENERAL INFORMATION OPERATIONAL CHECK WITH BATTERY INDICATOR

The generator is belt-driven by the engine. All en (BASE CLUSTER ONLY) /
gines use serpentine drive. When operating normally, the indicator bulb will
The amount of DC current produced by the gener come on when the ignition switch is turned to the
ator is controlled by the Powertrain Control Module RUN or START position. After the engine starts, the
(Fig. 1). indicator bulb goes off. With the engine running, the
charge indicator should come on only when there is a
problem in the charging system (base cluster only).
MALFUNCTION OPERATIONAL CHECK WITH VOLTMETER
INDICATOR
LAMP
When the ignition switch is turned to the RUN po
sition, battery potential will register on the voltme
ter. During engine cranking a lower voltage will
appear on the meter. With the engine running, a
DIAGNOSTIC SCAN voltage reading higher than the first reading (igni
TOOL
tion in RUN) should register.
DIAGNOSTIC PROCEDURES
If the indicator operates abnormally, or if an un
dercharged or overcharged battery condition occurs,
the following procedures may be used to diagnose the
charging system.
Remember that an undercharged battery is often
POWERTRAIN CONTROL
caused by:
MODULE • accessories being left on overnight
• or by a defective switch
which allows a bulb, such as a trunk or glove box
light, to stay on (refer to Ignition Off Draw).
VISUAL INSPECTION
• Inspect condition of battery cable terminals, bat
tery posts, connections at engine block, starter motor
BATTERY solenoid and relay. They should be clean and tight.
GENERATOR J938A-23 Repair as required.
• Inspect all fuses in the fuse block for tightness in
Fig. 1 Charging System Components (Typical) receptacles. They should be properly installed and
All vehicles are equipped with On Board Diagnos tight. Repair or replace as required.
tics (OBD). All OBD sensing systems are monitored • Inspect the electrolyte level in the battery and add
by the Powertrain Control Module. The Powertrain water if necessary.
Control Module will store in electronic memory any • Inspect generator mounting bolts for tightness. Re
detectable failure within the monitored circuits. Re place or torque bolt as required (refer to Torque
fer to USING ON-BOARD DIAGNOSTIC SYSTEM Specifications).
• Inspect generator drive belt condition and tension.
in this group for more information.
Tension or replace belt as required. Refer to Belt
Tension Specifications.
• Inspect connection at generator B + output. It
should be clean and tight. Repair as required.
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
GENERATOR OUTPUT WIRE RESISTANCE back of generator (Fig. 2). (This will generate a diag
TEST nostic trouble code (DTC)).
Generator output wire resistance test will show
amount of Voltage Drop across generator output wire CAUTION: Do not connect green/orange A142 lead
between generator BAT terminal and battery posi of wiring to ground. Refer to Group 8W - Wiring Di
tive post. agrams for more information.
PREPARATI01 (8) Connect an engine tachometer and connect neg

(1) Before starting test make sure vehicle has a ative cable to battery.
fully charged battery. Test and procedures on how to (9) Connect a variable carbon pile rheostat be
check for a fully charged battery are shown in Bat tween battery terminals. Be sure carbon pile is in
tery section of this Group. "Open" or "Off' position before connecting leads. See
(2) Turn OFF ignition switch. Battery Section, Load Testing for instructions.
(3) Disconnect negative cable from battery.
TEST
(4) Disconnect generator output wire from genera
(1) Start engine. Immediately after starting, re
tor output Battery terminal.
duce engine speed to idle.
(5) Connect a 0-150 ampere scale D.C. ammeter in
(2) Adjust engine speed and carbon pile to main
series between generator BAT terminal and discon
tain 20 amperes flowing in circuit. Observe voltmeter
nected generator output wire (Fig. 2). Connect Posi
reading. Voltmeter reading should not exceed 0.5
tive lead to generator BAT terminal and Negative
volts.
lead to disconnected generator output wire.
(6) Connect Positive lead of a test voltmeter RESULTS
(Range 0-18 volts minimum) to disconnected genera If a higher voltage drop is indicated, inspect, clean
tor output wire. Connect negative lead of test voltme and tighten all connections between generator BAT
ter to battery positive cable at positive post. terminal and battery Positive post. A voltage drop
(7) Connect one end of a Jumper Wire to ground test may be performed at each connection to locate
and with other end probe green K20 lead wire at connection with excessive resistance. If resistance
GROUNDi
CHASSIS ~
GROUND
J938A-19
Fig. 2 Generator Output Wire Resistance Test (Typical)

tested satisfactorily, reduce engine speed, turn off tive lead to generator BAT terminal and negative
carbon pile and turn off ignition switch. lead to disconnected generator output wire.
(1) Disconnect negative cable from battery. (5) Connect positive lead of a test voltmeter (range
(2) Remove test ammeter, voltmeter, carbon pile, 0-18 volts minimum) to generator BAT terminal.
and tachometer. (6) Connect negative lead of test voltmeter to a
(3) Remove "Jumper Wire". good ground.
(4) Connect generator output wire to generator (7) Connect an engine tachometer and connect bat
BAT terminal post. Tighten to 5 to 6 N*m (45 to 75 tery negative cable.
in. lbs.). (8) Connect a variable carbon pile rheostat be
(5) Connect negative cable to battery. tween battery terminals. Be sure carbon pile is in
(6) Use DRB II Scan Tool to erase DTC. OPEN or OFF position before connecting leads. See
Battery section, Load Testing for instructions.
GENERATOR OUTPUT TEST (9) Connect one end of a Jumper Wire to ground
Generator output test determines whether genera and with other end probe green K20 lead wire at
tor can deliver its rated current output. back of generator (Fig. 3). (This will generate a diag
nostic trouble code).
PREPARATION
(1) Before starting any tests make sure vehicle has CAUTION: Do not connect green/orange A142 lead
a fully charged battery. Test and procedures on how of wiring to ground. Refer to Group 8W - Wiring Di
to check for a fully charged battery are shown in agrams for more information.
Battery section of this Group.
(3) Disconnect generator output wire at the gener TEST
ator battery terminal. (1) Start engine. Immediately after starting reduce
(4) Connect a 0-150 ampere scale D.C. ammeter in engine speed to idle.
series between generator BAT terminal and discon (2) Adjust carbon pile and engine speed in incre
nected generator output wire (Fig. 3). Connect Posi ments until a speed of 1250 rpm and voltmeter read
ing of 15 volts is obtained.
T O P O W E R T R A I N A U T O S H U T D O W N RELAY
CONTROL MODULE
VOLTAGE TERMINAL
Jf_
J938A-16
Fig. 3 Generator Current Output Test (Typical)

8A - 18 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CAUTION: Do not allow voltage meter to read above DIAGNOSTIC TROUBLE CODES (DTC)
16 volts. Diagnostic trouble codes are two-digit numbers
flashed on Malfunction Indicator (Check Engine)
(3) The ammeter reading must be within limits lamp that identify which circuit is bad. In most cases
shown in generator specifications in back of this they do not identify which component in a circuit is
group for that size of generator being tested. bad. A fault description can be read using the DRB II
Scan Tool. Refer to Group 14 - Fuel Systems for more
RESULTS
information. Therefore, a DTC is only a result, not
(1) If reading is less than specified and generator
necessarily the reason for the problem. In some
output wire resistance is not excessive, generator
should be replaced; refer to Group 8C - Generator cases, because of the design of the driveability test
Service for information. procedure, a DTC can be the reason for the problem.
(2) After current output test is completed reduce It is important that the test procedure be followed to
engine speed, turn off carbon pile and turn off igni understand what the DTC of the on-board diagnostic
tion switch. system are trying to tell.
(4) Remove test ammeter, voltmeter, tachometer HOW TO USE MALFUNCTION INDICATOR (CHECK
and carbon pile. ENGINE) LAMP FOR DIAGNOSTIC TROUBLE
(5) Remove Jumper Wire (Fig. 3). CODES
(6) Connect generator output wire to generator To start this function, cycle the ignition switch on-
BAT terminal post. Tighten nut to 5-6 N-m (45-75 in. off-on-off-on within 5 seconds and any fault stored in
lbs.). the PCM will be displayed. The Check Engine lamp
(7) Connect negative cable to battery. will display a DTC by flashing on and off. There is a
(8) Use DRB II Scan Tool to erase DTC. short pause between flashes and a longer pause be
tween digits. All codes displayed are two digit num
USING ON-BOARD DIAGNOSTIC SYSTEM bers with a 4 second pause between codes.
An example of a code is as follows:
OPERATION OF ONBOARD DIAGNOSTIC (1) Lamp on for 2 seconds, then turns off.
SYSTEM (2) Lamp flashes 4 times pauses and then flashes 1
The Powertrain Control Module (PCM) monitors time.
critical input and output circuits of the charging sys (3) Lamp pauses for 4 seconds, flashes 4 times,
tem making sure they are okay. Some are checked pauses and then flashes 7 times.
continuously and some are checked only under cer The 3 codes are 41, 46 and 47. Any number of
tain conditions. codes can be displayed as long as they are in mem
If on-board diagnostic system senses that one criti ory. The lamp will flash until all are displayed (55 =
cal circuit is bad, during a predetermined amount of End of test).
time in the monitoring cycle, it will put a diagnostic
trouble code into memory. Each input and output cir CHARGING SYSTEM DIAGNOSTIC TROUBLE
cuit monitored by the on-board diagnostic system has CODES
its own diagnostic trouble code. The diagnostic trou See Generator Diagnostic Code Chart for diagnostic
ble code (DTC) will stay in memory as long as the trouble codes which apply to the charging system.
circuit continues to be bad. If the problem does not Refer to the Powertrain Diagnostic Procedures Man
happen again after the fault code is put into memory, ual to diagnose an On-Board Diagnostic System,
the PCM is programmed to clear the memory after Trouble Code.
50 engine starts.
CHARGING SYSTEM DIAGNOSTICS

UNS rEADY
IMPROPER
CHARGING OR LOW o\/ER NOISY
ALTERNATOR
CHAF{GING CHAR.GING
CHECK BATTERY
CONDITION TEST GROUNDED W O R N OR
SEE BATTERY GENERATOR GENERATOR FIELD FRAYED
SECTION FOR OUTPUT WIRE WIRE, FIELD DRIVE BELT
DETAILS RESISTANCE TERMINAL, OR
CONNECTIONS
CORRODED CHARGING
BATTERY CABLES GENERATOR
RESISTANCE REFER TO MOUNTING
OR TERMINALS TOO HIGH USING ON-BOARD LOOSE
DIAGNOSTIC
SYSTEM
DRIVE BELTS CORRODED OR

LOOSE SHORTED CABLES
OR HIGH FAULTY FAULTY
RESISTANCE GENERATOR GENERATOR
ACROSS FUSIBLE
LOOSE OR LINK
CORRODED
WIRING
CONNECTIONS AT
GENERATOR
RESISTANCE *FOR MORE INFORMATION REFER TO
O.K. THE POWERTRAIN DIAGNOSTIC PROCEDURES
LOOSE OR MANUAL COVERING THE VEHICLE INVOLVED
CORRODED
WIRING • S E E GROUP 8 W , WIRING DIAGRAMS FOR
CONNECTIONS AT TEST CIRCUIT AND COMPONENT INFORMATION
TERMINAL BLOCK GENERATOR
CURRENT
OUTPUT
LOOSE
CHASSIS TO
BATTERY GROUND
CABLE CURRENT
OUTPUT
O.K.
LOOSE
GENERATOR
GROUND WIRE
REFER TO
USING ON-BOARD
DIAGNOSTIC
LOOSE OR SYSTEM
CORRODED
WIRING
CONNECTIONS AT
BULKHEAD FAULTY
DISCONNECT GENERATOR
CHECK FOR
APPROXIMATELY
12 VOLTS AT FIELD
INPUT BRUSH
TERMINAL W I H T
IGNITION SWITCH
"ON" J938A-10
GENERATOR DIAGNOSTIC TROUBLE CODE (DTC)
Malfunction W h e n Monitored Sensor

Indicator B y t h e Logic Actuator Read
Type Lamp Circuit Module W h e n Put Into Memory Test Test
Generator Field All the time when An open or shorted condition in

41 Fault Yes Control the ignition switch the generator field Yes None
(Charging System) is on. control circuit.
If the battery sense voltage is

Charging System All the time when the more than 1 volt above the
46 Fault Yes None Yes
Voltage engine is running. desired control voltage for
more than 2 0 seconds.
Battery voltage 1 volt less

than set point during engine
Charging System Engine rpm above operation and no change in
47 Fault Yes None Yes
Voltage 1,500 rpm voltage during internal PCM
test performed on generator
field.
J938A-20
J BATTERY/STARTER/GENERATOR SERVICE 8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY SERVICE PROCEDURES 1 GENERATOR SERVICE PROCEDURES 7

ENGINE STARTER MOTOR SERVICE SPECIFICATIONS 10
PROCEDURES 4
BATTERY SERVICE PROCEDURES

GENERAL INFORMATION
This section covers Battery removal and installa
tion procedures only. For diagnostic procedures, refer
Group 8A - Battery/Starting/Charging Systems Diag
nostics.
BATTERY MAINTENANCE
(1) Inspect cable terminals for corrosion and dam
age. Remove the corrosion using a wire brush, or
post and terminal cleaner, and a sodium bicarbonate/
water solution. Replace cables that have damaged or
deformed terminals.
Be sure vents are installed when washing bat
tery to prevent solution from entering battery.
(2) Clean outside of battery case if the original
battery is to be installed. Clean top cover with di
luted ammonia or a sodium bicarbonate/water solu
tion to remove acid film (Fig. 1). Flush with clean
water. Ensure that cleaning solution does not enter
cells. BATTERY RK108
(3) Remove corrosion from the terminals with a
wire brush or post and terminal cleaner (Figs. 2 and Fig. 1 Cleaning Battery
3). Inspect the case for cracks or other damage that (3) If necessary, use a puller to remove cable ter
would result in leakage of electrolyte. minal clamps. Remove negative cable terminal clamp
(4) Check electrolyte level in the battery. Use a first.
putty knife or other suitable wide tool to pry filler
caps off low maintenance battery (Fig. 4). Do not use WARNING: W E A R A S U I T A B L E P A I R O F R U B B E R
a screwdriver. Add distilled water to each cell until G L O V E S (NOT T H E H O U S E H O L D T Y P E ) W H E N R E
the liquid reaches the bottom of the vent well. DO MOVING A B A T T E R Y B Y HAND- S A F E T Y G L A S S E S
NOT OVERFILL. ALSO SHOULD B E WORN. IF T H E B A T T E R Y I S
(5) Operate the engine immediately after adding C R A C K E D O R L E A K I N G T H E E L E C T R O L Y T E CAN
water (particularly in cold weather) to assure proper B U R N T H E S K I N AND E Y E S .
mixing of the water and acid.
(4) Remove battery hold-downs and battery from
BATTERY REPLACEMENT vehicle (Figs. 5 and 6).
(5) Inspect battery tray and holddowns for corro
REMOVAL sion. Remove corrosion using a wire brush and a so
(1) Make sure ignition switch is in OFF position dium bicarbonate/water solution. Paint any exposed
and all battery feeds are OFF. bare metal. Replace damaged components (Figs. 7, 8).
(2) Loosen the cable terminal clamps.
8B - 2 BATTERY/STARTER/GENERATOR SERVICE J
Fig. 4 Removing Filler Cap
Fig. 2 Cleaning Battery Post
J898A-3
Fig. 5 Battery Holddown—XJ

(4) Ensure that tang at battery base is positioned
in tray properly before tightening holddown.
CAUTION: It i s imperative that the cables are con

nected to the battery positive-to-positive and nega-
tive-to-negative. Reverse polarity will damage the
generator diodes and radio(s).
Fig. 3 Cleaning Battery Terminals
INSTALLATION (5) Place felt washer on positive battery terminal.
(1) Refer to Specifications to determine if battery (6) Connect positive cable first. Then connect neg
has correct classification and rating for the vehicle, ative cable. Tighten both cable terminal bolts to 8.5
(2) Use a hydrometer to test the battery electro N-m (75 in. lbs.).
lyte. Charge battery if necessary. (7) Apply a thin coating of petroleum jelly or chas
(3) Position battery in tray. Ensure that positive sis grease to cable terminals and battery posts.
and negative terminals (posts) are correctly located. (8) Inspect negative cable connections on engine
The cables must reach their terminals (posts) with and vehicle body for condition, security and continu
out stretching (Figs. 5 and 6). ity.
BATTERY/STARTER/GENERATOR SERVICE 8B - 3
J898A-6
Fig. 7 Battery Tray-XJ

IB - 4 BATTERY/STARTER/GENERATOR SERVICE J
E N G I N E STARTER MOTOR SERVICE P R O C E D U R E S
INDE1
page page
2.5L Starter G e n e r a l Information 4 General Information 4
2.5L Starter Motor Removal/Installation 5 Park/Neutral Position Switch 6
4.0L General Starter Information 6 Starter Relay Replacement 4
4.0L Starter Motor Removal/Installation 6
GENERAL INFORMATION
This section will cover the Starting System compo
nent service procedures only. For diagnostic proce
dures, refer to Group 8A - Battery/Starting/Charging
Systems Diagnostics.
Starting system components: battery, starter mo
tor, starter relay switch, solenoid, ignition switch,
connecting wires and battery cables. A park/neutral
position switch is used with automatic transmissions.
STARTER RELAY REPLACEMENT

The starter relay is located in the Power Distribu
tion Center (Figs. 1 and 2). Refer to underside of
Power Distribution Cover for relay location.
(2) Replace relay.
(3) Connect negative cable to battery.
(4) Test relay operation.
Fig. 2 Power Distribution Center— YJ

A planetary gear system (intermediate transmis
sion) between the electric motor and pinion shaft
makes it possible to reduce the dimensions of the
starter. This also makes it possible to obtain a higher
rotational speed to produce the same torque at the
pinion.
The permanent magnet field consists of six two-
component high strength magnets. The magnets are
aligned according to their polarity and are perma
nently fixed in the stator frame.
The brush holder plate consists of a plastic base
plate with four tubular brush holders.
This unit is highly sensitive to hammering, shocks
and external pressure.
CAUTION: T h e starter motor M U S T NOT B E

C L A M P E D in a vise by the stator frame. Doing s o
Fig. 1 Power Distribution Center—XJ may damage the magnets. It may be clamped by the
mounting flange ONLY.
2.5L STARTER GENERAL INFORMATION
The 2.5L engine starter motor incorporates several
unique features to create an efficient, lightweight
unit.
CAUTION: Do not connect starter motor incorrectly SOLENOID

when tests are being performed. The magnets may
be damaged and rendered unserviceable.
• Ensure cleanliness when performing repairs.

• Metal chips are attracted by the magnets and may
not be completely removed from the stator frame.
Chips in the ring gear can lead to failure of the
starter.
2.5L STARTER MOTOR REMOVAL/INSTALLATION
MJ-2.SL ENGINE
(2) Remove exhaust clamp from bracket (Fig. 3).
(3) Remove nut and bolt from forward end of brace
rod (automatic transmission only).
(4) Remove nut from lower end of brace rod and
(automatic transmission only). J938B-24
(5) Remove brace rod and bracket (automatic
transmission only). Fig. 4 Starter Motor Removal/Installation—2.5L XJ
(6) Remove nut, bolt and bracket from bell housing (2) Disconnect battery cable from starter motor
(manual transmission only). B+ terminal (Fig. 5).
(3) Disconnect solenoid feed wire.
(4) Remove starter motor mounting screws.
(5) Remove starter motor at flywheel (drive plate)
housing.
Fig. 3 Exhaust Clamp and Brace Removal—2.5L XJ

(7) Disconnect battery cable and solenoid feed wire
from solenoid (Fig. 4).
(8) Remove mounting starter motor mounting
Fig. 5 Starter Motor Removal/Installation—2.5L YJ
bolts.
(9) To install starter motor, reverse the removal (6) To install starter motor, reverse removal proce
procedures and torque mounting hardware as shown. dures and torque mounting hardware as shown.
(10) Connect negative cable to battery. (7) Connect negative cable to battery.
YJ-2.SL ENGINE
8B - 8 1ATTERY/STARTER/GENERAT0R SERVICE
4.0L GENERAL STARTER INFORMATION (3) Disconnect battery wire and solenoid feed wire.
The Mitsubishi starter motor is a light-weight unit (4) Remove starter lower mounting bolt (Fig. 6).
featuring a planetary gear drive and permanent (5) Remove starter upper mounting bolt and re
magnets for current induction. move starter.
The planetary gear drive is splined to both the ar
mature shaft and overrunning clutch. Starter torque
is transmitted to the overrunning clutch pinion
through the planetary gears which provide higher ro
tational speeds.
The starter magnetic field is produced by six per
manent magnets. The magnets are mounted in the
armature frame and positioned according to polarity.
They are permanently attached to the frame and are
not removable.
The starter motor is activated by a solenoid
mounted on the overrunning clutch housing.
This unit is highly sensitive to hammering, shocks,
and external pressure.
CAUTION: The starter motor MUST NOT B E
CLAMPED in a vise by the stator frame. Doing s o
may damage the magnets. It may be clamped by the
mounting flange ONLY.
CAUTION: Do not connect the starter motor incor

rectly when performing tests. T h e magnets may be
Fig. 6 Starter Motor Removal/Installation (Typical)
damaged and rendered unserviceable.
(6) To install starter motor, reverse the removal
• Ensure cleanliness when performing repairs. procedures and torque mounting hardware as shown.
• Metal chips are attracted by the magnets and may (7) Remove support and lower vehicle.
not be completely removed from the stator frame. (8) Install negative cable to battery.
Chips in the ring gear can lead to failure of the
starter. PARK/NEUTRAL POSITION SWITCH
Refer to Group 21 for diagnostic, removal and in
4.0L STARTER MOTOR REMOVAL/INSTALLATION stallation procedures.
(1) Disconnect negative cable from battery. Cheek linkage adjustment before replacing the
(2) Raise and support vehicle. switch.
il BATTERY/STARTER/GENERATOR SERVICE 8B - 7
GENERATOR SERVICE PROCEDURES

GENERAL BACK VIEW 27 N*AA
The generator is belt-driven by the engine. All en W (20 FT-LBS)
gines use serpentine drive. This section will cover

generator removal and installation. The generator is
not serviceable. Information covering on-vehicle test
ing can be found in Group 8A - Battery/Starting/
Charging Systems Diagnostics.
GENERATOR REMOVAL AND INSTALLATION

WARNING: FAILURE TO DISCONNECT NEGATIVE
RELIEVE
CABLE FROM BATTERY BEFORE DISCONNECTING
TENSION B Y
RED (OUTPUT) WIRE CONNECTOR FROM GENER T U R N I N G ADJUSTING
ATOR CAN RESULT IN INJURY. BOLT.
ALL YJ AND MJ WITH 2.5L ENGINE

Belt tension is adjusted at the power steering pump
A D J U S T BELT
(or idler pulley if not equipped with power steering). TENSION BY
To adjust belt tension or to replace belt: TURNING ADJUSTING
(1) Disconnect negative cable from battery. BOLT. J898B-8
(2) Loosen rear mounting bolts (Fig. 1 or Fig. 2).
Fig. 2 Idler Pulley Rear Mounting Bolts—Except XJ
With 4.0L
PIVOT BOLT
POWER
STEERING
PUMP
PULLEY
\ \
POWER ADJUSTING
STEERING BOLT
J9107-39
PUMP
J9107-38
Fig. 1 P.S Pump Rear Mounting Bolts—Except XJ LOCKNUT
With 4.0L
Fig. 3 P.S Pump Front Mounting Bolts—Except XJ
(3) Loosen power steering pump pivot bolt and lock With 4.0L
nut (Fig. 3 or Fig. 4).
CAUTION: When installing a serpentine accessory
(4) Loosen adjusting bolt to remove belt.
drive belt, the belt M U S T be routed correctly. T h e
(5) Remove B + terminal nut, 2 field terminal
engine may overheat because the water pump will
nuts, ground and harness hold down nuts (Fig. 5).
be rotating in the wrong direction if the belt i s in
Remove wire connector assembly.
stalled incorrectly. Refer to the appropriate acces
(6) Remove 2 generator mounting bolts and re
sory drive belt schematic f o r the correct belt
move generator from vehicle.
routing (Group 7).
(7) Install generator with 2 mounting bolts. Torque
bolts to 55 N*m (41 ft. lbs.). (9) Place serpentine belt over pulley.
(8) Attach generator wires. (10) Belt tension adjustment is made at power
steering pump or idler pulley (Figs. 1 or 2).
CAUTION: Never force a belt over a pulley rim u s
(11) Turn adjusting bolt until belt has correct ten
ing a screwdriver as the synthetic fiber may be
damaged.
sion as given in Group 7 - Cooling System.
8B - I BATTERY/STARTER/GENERATOR SERVICE J
Fig. 6 P.S Pump-Rear-Mounting Bolts—XJ With 4.0L

Fig. 4 Idler Pulley Front Mounting Bolts—Except XJ
With 4.0L
Fig. 5 Remove or Install Connector Assembly

(12) Tighten rear mounting bolts, pivot bolt, and
J898B-5
lock nut to 27 N*m (20 ft. lbs.) torque.
(13) Remove support and lower vehicle. Fig. 7 P.S Pump Front Mounting Bolts—XJ With
(14) Connect negative cable to battery. 4.0L
XJ WITH 4.0L ENGINE (6) Remove B + terminal nut, 2 field terminal
Belt tension is adjusted at the power steering pump nuts, ground and harness hold down nuts (Fig. 8).
(or idler pulley if not equipped with power steering). Remove wire connector assembly.
To adjust belt tension or to replace belt: (7) Remove 2 generator mounting bolts and re
(1) Disconnect negative cable from battery. move generator from vehicle.
(2) Loosen rear mounting bolts (Fig. 6). (8) Install generator with two mounting bolts.
(3) Loosen power steering pump pivot bolt and lock Torque bolts to 55 N«m (41 ft. lbs.).
nut (Fig. 7). (9) Attach generator wires.
(4) Loosen adjusting bolt to remove belt.
(5) Raise and support vehicle,
CAUTION: Never force a belt over a pulley rim u s

ing a screwdriver as the synthetic fiber may he
damaged.

drive belt, the belt M U S T be routed correctly. T h e
engine may overheat because the water pump will
be rotating in the wrong direction if the belt i s in
stalled incorrectly. Refer to the appropriate acces
sory drive belt schematic f o r the correct belt
routing (Group 7).
(10) Place serpentine belt over pulley.

(11) Belt tension adjustment is made at idler pul
ley (Fig. 6).
(12) Turn adjusting bolt until belt has correct ten
Fig. 8 Remove or Install Connector Assembly sion as given in Group 7 - Cooling System.
(13) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 N*m (20 ft. lbs.) torque.
(14) Remove support and lower vehicle.
8B - 10 BATTERY/STARTER/GENERATOR SERVICE
SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS BATTERY TORQUE SPECIFICATIONS
Cold Resenre Description Torque

Group Vehicle
Crank Capacity Ingine
Size Series Battery Strap Screw 2 N*m (20 in. lbs.)
AMPS (Min.)
Battery Tray Nut 2 N*m (20 in. lbs.)
58 430 80 2.5L & 4.0L All
Battery Clamp Nut 2 N*m (20 in. lbs.)
58 500 85 2.5L, 4.0L All J928A-7
J928A-1
BELT TENSION
Type of Belt New Belt N (Ibs-f) Used Belt (Ibs-f)

Serpentine Belt 800-900 (180-200) 623-712 (140-160)
V-Belt 533-711 (120-160) 400-511 (90-115)
J918C-17
4.0L ENGINES STARTER MOTOR COLD CRANKING

4.0L STARTER MOTOR AND SOLENOID TEST SPECIFICATIONS
ING SPECIFICATIONS
Battery Test Voltage 12.5 Volts
e
Description Specifkaftans @ 20 °C (68 F) Cold Cranking Voltage (Min.) 9.6 Volts
No Load Test With
Cold Cranking Amps 160 Amps
11.2 volts
Max. Amps 90 J918B-19
Min. RPM 2500
Solenoid Hold-in STARTER MOTOR TORQUE SPECIFICATIONS
Winding Voltage 3.5 Min.
Pull-in Winding COMPONENTS TORQUE
Voltage 7.8 Max.
J928B-25 Starter Motor
45 N»m (33 ft. lbs.)
Mounting Bolts
STARTER MOTOR COLD CRANKING
Starter Solenoid
SPECIFICATIONS 10 N T n (90 in. lbs.)
Battery Cable Nut
Starter Solenoid B +
6 N T n (55 in. lbs.)
Battery Test Voltage 12.5 Volts Nut
J928B-23
Cold Cranking Voltage GENERATOR SPECIFICATIONS
9.6 Volts
(Minimum)
TORQUE SPECIFICATIONS
Cold Cranking Amps 130 Amps

COMPONENT TORQUE
J918B-17 Generator Mounting
38 N m (28 ft. lbs.)
Bolts
STARTER MOTOR TORQUE SPECIFICATIONS
Power Steering Pump
(or Idler Pulley) 27 N m (20 ft. lbs.)
Mounting Bolts
COMPONENTS TORQUE
J938B-12
Starter Motor Upper 55 N*m (40 ft. lbs.)
Mounting Bolts Lower 41 N*m (30 ft. lbs.) OUTPUT VOLTAGE SPECIFICATIONS
Starter Solenoid 10 N T n (90 in. lbs.)
Battery Cable Nut PCM Temperature Acceptable
°C(°F) Voltage Range
Starter Solenoid B + 6 N*m (55 in. lbs.)
Nut - 4 0 to - 6.7 ( - 40 to 20) 14.5 to 15.0
J938B-22
- 6.7 to 26.7 (20 to 80) 13.87 to 15.0
2.5L ENGINES
26.7 to 60 (80 to 140) 13.25 to 14.37
2.SL STARTER MOTOR SPECIFICATIONS
60 to 71.1 (140 to 160) 13.25 to 13.75
Description Specifications @ 2 0 °C (68 °F)
J938B-25
No Load Test With
11.5 volts
Max. Amps 75
Min. RPM 2900 Type Part Number Engine Rating
Solenoid Hold-in
Winding Voltage 2.6V-3.5V Max. Nippondenso 56005684 2.5L & 4.0L 75
Solenoid Pull-in Nippondenso 56005685 2.5L & 4.0L 90

Winding Voltage 6V-7.5V Max.
J918C-11
Starter Type DW 1.4
J928B-24
J IGNITION SYSTEMS 8D - 1
IGNITION SYSTEMS
CONTENTS
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES . . . . . . . B mm

OPERATION . 1 IGNITION SWITCH—ALL MODELS 29 •
COMPONENT REMOVAL/INSTALLATION 11 SPECIFICATIONS 32 •
COMPONENT IDENTIFICATION/SYSTEM OPERATION
INDEX
page page
Automatic Shut Down (ASD) Relay . . . . . . . . . . . . 1 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . 1 Intake Manifold Charge Air Temperature Sensor . . 5
Crankshaft Position Sensor 2 Manifold Absolute Pressure (MAP) Sensor ...... 5
Distributors 3 Powertrain Control Module (PCM) 6
Engine Coolant Temperature Sensor 4 Throttle Position Sensor 6
General Information 1
GENERAL INFORMATION IGNITION SYSTEMS

Throughout this group, references are made to par A multi-port, fuel injected engine is used on all
ticular vehicle models by alphabetical designation models. The ignition system is controlled by the Pow
(XJ or YJ) or by the particular vehicle nameplate. A ertrain Control Module (PCM) on all engines. The
chart showing a breakdown of alphabetical designa PCM was formerly referred to as the SBEC or engine
tions is included in the Introduction group at the be controller.
ginning of this manual. The ignition system consists of:
This section of the group, Component Identifica • Spark Plugs
tion/System Operation, will discuss ignition system • Ignition Coil
operation and will identify ignition system compo • Secondary Ignition Cables
• Ignition distributor (contains rotor and camshaft
nents.
position sensor)
For diagnostic procedures and adjustments, refer to
• Powertrain Control Module (PCM)
the Diagnostics/Service Procedures section of this
• Crankshaft Position Sensor
group.
For removal and installation of ignition system AUTOMATIC SHUT DOWN (ASD) RELAY
components, refer to the Component Removal/Instal The automatic shut down (ASD) relay is located in
lation section of this group. the Power Distribution Center (PDC) near the bat
For other useful information, refer to On-Board Di tery (Fig. 1 or 2). As one of its functions, it will sup
agnostics in the General Diagnosis sections of Group ply battery voltage to the ignition coil. The ground
14, Fuel System in this manual. circuit for the ASD relay is controlled by the Power-
For operation of the DRB II Diagnostic Scan Tool, train Control Module (PCM). The PCM regulates
refer to the appropriate Powertrain Diagnostic Proce ASD relay operation by switching the ground circuit
dures service manual. on-and-off.
An Ignition specifications section is included at the
end of this group. A general Maintenance Schedule CAMSHAFT POSITION SENSOR
(mileage intervals) for ignition related items can be The camshaft position sensor is located in the igni
found in Group 0, Lubrication and Maintenance. This tion distributor (Figs. 3 or 4) on all engines.
schedule can also be found in the Owners Manual. 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
8D - 2 IGNITION SYSTEMS J
SENSOR HARNESS
J9114-91
Fig. 1 PDC-XJ Models
Fig. 2 PDC-YJ Models

rotating pulse ring (shutter) on the distributor shaft
(Fig. 4). The pulse ring rotates 180 degrees through
the sync signal generator. Its signal is used in con
junction with the crankshaft position sensor to differ
entiate between fuel injection and spark events. It is
also used to synchronize the fuel injectors with their
respective cylinders.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following oc
curs: The interruption of magnetic field causes the
voltage to switch high resulting in a sync signal of
approximately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following oc
curs: The change of the magnetic field causes the
sync signal voltage to switch low to 0 volts.
For component testing, refer to the Diagnostics/Ser Fig. 4 Distributor—Typical
vice Procedures section of this group. CRANKSHAFT POSITION SENSOR
For removal and installation of this component, re The crankshaft position sensor is mounted to the
fer to the Component Removal/Installation section of transmission bellhousing at the left/rear side of the
this group. engine block (Figs. 5, 6 or 7).
J IGNITION SYSTEMS 80 - 3
Fig. 5 Crankshaft Position Sensor—2.5L Engine
Fig. 7 Crankshaft Position Sensor—4.0L Engine—YJ

models With Automatic Transmission
two groups of four pulses generated on 2.5L 4 cylin
der engines. There are 3 groups of four pulses gener
ated 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.
The engine will not operate if the PCM does not re
ceive a crankshaft position sensor input.
For component testing, refer to the Diagnostics/Ser
vice Procedures section of this group.
Fig. 6 Crankshaft Position Sensor—4.01 Engine—All For removal and installation of this sensor, refer to
Except YJ models With Automatic Transmission the Component Removal/Installation section of this
Engine speed and crankshaft position are provided group.
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the Pow DISTRIBUTORS
ertrain Control Module (PCM). The PCM interprets All engines are equipped with a camshaft driven
the sensor input to determine the crankshaft posi mechanical distributor containing a shaft driven dis
tion. The PCM then uses this position, along with tributor rotor. All distributors are equipped with an
other inputs, to determine injector sequence and ig internal camshaft position (fuel sync) sensor. This
nition timing. sensor provides fuel injection synchronization and
The sensor is a hall effect device combined with an cylinder identification.
internal magnet. It is also sensitive to steel within a The distributors on the 2.5L and 4.0L engines do
certain distance from it. not have built in centrifugal or vacuum assisted ad
vance. Base ignition timing and all timing advance
SENSOR OPERATION is controlled by the Powertrain Control Module
The flywheel/drive plate has groups of four notches (PCM). Because ignition timing is controlled by the
at its outer edge. On 4.0L 6 cylinder engines there PCM, base ignition timing is not adjustable on
are three sets of notches (Figs. 9 or 10). On 2.5L 4 any of these engines.
cylinder engines there are two sets of notches (Fig. The distributor is locked in place by a notch on the
8). distributor housing. The distributor holddown clamp
The notches cause a pulse to be generated when bolt passes through this notch when installed. Be
they pass under the sensor. The pulses are the input cause the distributor position is locked when in
to the PCM. For each engine revolution there are stalled, its rotational position can not be changed.
Fig. 10 Sensor Operation—4.0L Engine—YJ Models

With Automatic Transmission
For removal and installation of this component, re
fer to the Component Removal/Installation section of
this group.
IGNITION COIL
Battery voltage is supplied to the ignition coil pos
itive terminal from the ASD relay.
The Powertrain Control Module (PCM) opens and
closes the ignition coil ground circuit for ignition coil
operation.
Base ignition timing is not adjustable. By con
trolling the coil ground circuit, the PCM is able to
set the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
The ignition coil is mounted to a bracket on the
Fig. 9 Sensor Operation—4.0L Engine—All Except side of the engine (Fig. 11).
YJ Models With Automatic Transmission For component testing, refer to the Diagnostics/Ser
D o not attempt t o modify t h e distributor housing
to get distributor r o t a t i o n . D i s t r i b u t o r position
w i l l have no effect on i g n i t i o n t i m i n g .
this group.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing. ENGINE COOLANT TEMPERATURE SENSOR
The seal is not serviceable. The engine coolant temperature sensor provides an
For component testing, refer to the Diagnostics/Ser input voltage to the Powertrain Control Module
vice Procedures section of this group. (PCM) relating coolant temperature. The PCM uses
this input, along with inputs from other sensors, to
determine injector pulse width and ignition timing.
J IGNITION SYSTEMS 80 - S
Powertrain Control Module (PCM) indicating intake

manifold air temperature. The input from this sensor
is used along with inputs from other sensors to de
termine injector pulse width. As the temperature of
the air-fuel stream in the manifold varies, the sensor
resistance will change. This will result in a different
input voltage to the PCM. For more information, re
fer to Group 14, Fuel System.
This sensor is installed in the intake manifold (Fig.
13, 4.0L engine or Fig. 14, 2.5L engine).
-
-tX===/ IT IDLE A I R
-CONTROL MOTOR
114-21
Fig. 11 Ignition Coil—Typical

As coolant temperature varies, the sensor resistance
will change, resulting in a different input voltage to
the PCM.
When the engine is cold, the PCM will operate in
the Open Loop Cycle. It will demand slightly richer
air-fuel mixtures and higher idle speeds, until nor
mal operating temperatures are reached. Refer to
Modes Of Operation in Group 14, Fuel System for a
description of Open and Closed Loop operation.
This sensor is installed in the thermostat housing Fig. 13 Sensor Location—4.0L Engine
(Fig. 12).
THROTTLE
POSITION
SENSOR
J9314-140
Fig. 14 Sensor Location—2.5L Engine

Fig. 12 Coolant Temperature Sensor—Typical For component testing, refer to the Diagnostics/Ser
vice Procedures section of this group. fer to the Component Removal/Installation section of
For removal and installation of this component, re this group.
this group. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor reacts to absolute pressure in the
INTAKE MANIFOLD CHARGE AIR TEMPERATURE intake manifold and provides an input voltage to the
SENSOR Powertrain Control Module (PCM). As engine load
The sensor element extends into the intake mani changes, manifold pressure varies, causing the MAP
fold air stream. It provides an input voltage to the sensor voltage to change. This change results in a
8D - 6 IGNITION SYSTEMS
different input voltage to the PCM. The input volt PCM

age level supplies the PCM with information. This
relates to ambient barometric pressure during engine
start-up (cranking) and to engine load while the en
gine is running. The PCM uses this input, along with
inputs from other sensors, to adjust air-fuel mixture.
For more information, refer to Group 14, Fuel Sys
tem.
The MAP sensor is located in the engine compart
ment near the rear of engine cylinder head (valve)
cover (Fig. 15). It is connected to the throttle body
with a vacuum hose and to the PCM electrically.
Fig. 16 PCM Location—XJ Models
Fig. 15 MAP Sensor—Typical

fer to the Component Removal/Installation section of Fig. 17 PCM Location- YJ Models
this group.
For diagnostics, refer to the appropriate Powertrain
POWERTRAIN CONTROL MODULE (PCM) Diagnostic Procedures service manual for operation
The PCM was formerly refered to as the the SBEC of the DRB II scan tool.
or engine controller. On XJ models, the PCM is lo
cated in the engine compartment next to the air THROTTLE POSITION SENSOR
cleaner (Fig. 16). On YJ models, the PCM is located The sensor is mounted on the throttle body (Figs.
in the engine compartment behind the windshield 18 or 19). It is connected to the throttle blade shaft.
washer fluid reservoir (Fig. 17). The sensor is a variable resistor. It provides the Pow
The ignition system is controlled by the PCM. ertrain Control Module (PCM) with an input signal
Base ignition timing by rotation of distributor (voltage) that represents throttle blade position. As
is not adjustable. The PCM opens and closes the ig the position of the throttle blade changes, the resis
nition coil ground circuit to operate the ignition coil. tance of the sensor changes.
This is done to adjust ignition timing, both initial The PCM supplies approximately 5 volts to the
(base) and advance, for changing engine operating sensor. The sensor output voltage (input signal to the
conditions. PCM) represents the throttle blade position. The
The amount of electronic spark advance provided PCM receives an input signal voltage from the sen
by the PCM is determined by five input factors: Cool sor. This will vary in an approximate range of from 1
ant temperature, engine rpm, manifold air tempera volt at minimum throttle opening (idle), to 4 volts at
ture, intake manifold absolute pressure and throttle wide open throttle. Along with inputs from other sen
position. sors, the PCM uses the sensor input to determine
current engine operating conditions. It will also ad
just fuel injector pulse width and ignition timing.
this group.
j IGNITION SYSTEMS 8D - 7
Fig. 18 Throttle Position Sensor-2.5L Engine Fig. 19 Throttle Position Sensor-4.0L Engine
For component testing, refer to the Diagnostics/Ser- For removal and installation of this component, re-
vice Procedures section of this group. fer to the Component Removal/Installation section of
this group.
DIAGNOSTICS/SERVICE P R O C E D U R E S
INDEX
page page
Automatic Shut Down (ASD) Relay 8 Ignition Timing 13
Camshaft Position Sensor Test . . . . . . . . . . . . . . . 8 Intake Manifold Charge Air Temperature Sensor
Crankshaft Position Sensor Test .............. 9 Test . 14
Distributor Cap ........................... 9 Manifold Absolute Pressure (MAP) Sensor Test . 14
Distributor Rotor 10 Oxygen Sensor Tests 18
Engine Coolant Temperature Sensor Test . . . . . . 11 Powertrain Control Module (PCM) 15
General Information 8 Spark Plug Secondary Cables . . . . . . . . . . . . . . . 17
Ignition Coil 10 Spark Plugs 15
Ignition Secondary Circuit Diagnosis 11 Throttle Position Sensor Test 18
GENERAL INFORMATION (2) Connect the negative (-) voltmeter lead into the
This section of the group, Diagnostics/Service Pro ground wire. For wire identification, refer to Group
cedures, will discuss basic ignition system diagnos 8W, Wiring Diagrams.
tics and service adjustments. (3) Set the voltmeter to the 15 Volt DC scale.
For system operation and component identification, (4) Remove distributor cap. Rotate (crank) engine
refer to the Component Identification/System Opera with starter until pulse ring (Fig. 1) enters the mag
tion section of this group. netic pickup on camshaft position sensor. Distributor
For removal or installation of ignition system com rotor should be pointed in 9 o'clock position. The
ponents, refer to the Component Removal/Installa movable pulse ring should now be within the sensor
tion section of this group. pickup.
For other useful information, refer to On-Board Di
agnostics in the General Diagnosis sections of Group 9 O'CLOCK CAMSHAFT POSITION
14, Fuel System in this manual.
For operation of the DRB II Diagnostic Scan Tool,
refer to the appropriate Powertrain Diagnostic Proce
dures service manual.
AUTOMATIC SHUT DOWN (ASD) RELAY

Refer to Relays—Operation/Testing in the Group
14, Fuel System section of this service manual.
CAMSHAFT POSITION SENSOR TEST

The camshaft position sensor is located in the dis
tributor on all engines.
To perform a complete test of this sensor and its
circuitry, refer to the DRB II diagnostic scan tool.
Also refer to the appropriate Powertrain Diagnostics
Procedures manual. To test the sensor only, refer to
the following:
2.5L OR 4.0L ENGINE
For this test, an analog voltmeter is needed. Do ROTOR J938D-8
not remove the distributor connector from the dis
tributor. Using small paper clips, insert them into Fig. 1 Pulse Ring/Rotor Position—Typical
the backside of the distributor wire harness connec
tor to make contact with the terminals. Be sure that (5) Turn ignition key to ON position. Voltmeter
the connector is not damaged when inserting the pa should read approximately 5.0 volts.
per clips. Attach voltmeter leads to these paper clips. (6) If voltage is not present, check the voltmeter
(1) Connect the positive ( + ) voltmeter lead into leads for a good connection.
the sensor output wire. This is at done the distribu (7) If voltage is still not present, check for voltage
tor wire harness connector. For wire identification, at the supply wire. For wire identification, refer to
refer to Group 8W, Wiring Diagrams. Group 8W, Wiring Diagrams.
(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 P C M connector
connected for this test.
(9) If voltage is still not present, perform vehicle
test using the DRB II diagnostic scan tool.
(10) If voltage is present at pin 7, but not at the
supply wire:
(a) Check continuity between the supply wire.
This is checked between the distributor connector
and pin 7 at the PCM. If continuity is not present,
repair the harness as necessary.
(b) Check for continuity between the camshaft
position sensor output wire and pin 44 at the PCM.
If continuity is not present, repair the harness as
necessary.
(c) Check for continuity between the ground cir Fig. 2 Crankshaft Position Sensor—2.5L Engine
cuit wire at the distributor connector and ground.
If continuity is not present, repair the harness as
necessary.
(11) While observing the voltmeter, crank the en
gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the en
gine is cranking. This verifies that the camshaft po
sition sensor in the distributor is operating properly
and a sync pulse signal is being generated.
If sync pulse signal is not present, replacement of
the camshaft position sensor is necessary.
For removal or installation of ignition system com
ponents, refer to the Component Removal/Installa
tion section of this group.
For system operation and component identification,
refer to the Component Identification/System Opera
tion section of this group. Fig. 3 Crankshaft Position Sensor—4.0L Engine—All
Except YJ models With Auto. Trans.
CRANKSHAFT POSITION SENSOR TEST
To perform a complete test of this sensor and its DISTRIBUTOR CAP
INSPECTION
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually inspect the cap for
the following:
cracks, carbon paths, broken towers, or damaged ro
The sensor is located on the transmission bellhous-
tor button (Figs. 6 and 7). Also check for white de
ing at the left/rear side of the engine block (Figs. 2, 3
posits on the inside (caused by condensation entering
or 4).
the cap through cracks). Replace any cap that dis
(1) Near the rear of intake manifold, disconnect
plays charred or eroded terminals. The machined
sensor pigtail harness connector from main wiring
surface of a terminal end (faces toward rotor) will in
harness.
dicate some evidence of erosion from normal opera
(2) Place an ohmmeter across terminals B and C
tion. Examine the terminal ends for evidence of
(Fig. 5). Ohmmeter should be set to IK-to-lOK scale
mechanical interference with the rotor tip.
for this test. The meter reading should be open (no
If replacement of the distributor cap is necessary,
resistance). Replace sensor if a low resistance is indi
transfer spark plug cables from the original cap to
cated.
the new cap. This should be done one cable at a time.
For removal or installation of ignition system com
Each cable is installed onto the tower of the new cap
ponents, refer to the Component Removal/Installa
that corresponds to its tower position on the original
ID 10 IGNITION SYSTEMS
Fig. 6 Cap Inspection—External— Typical
Fig. 4 Crankshaft Position Sensor—4.0L Engine—YJ

models With Auto. Trans.
Fig. 7 Cap Inspection—Internal— Typical
VIEW LOOKING INTO

CPS CONNECTOR J938D-7
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. 8 or 9).
DISTRIBUTOR ROTOR
Visually inspect the rotor (Fig. 10) for cracks, evi
dence of corrosion, or the effects of arcing on the
metal tip. Also check for evidence of mechanical in
terference with the cap. Some charring is normal on
the end of the metal tip. The silicone-dielectric-var-
Fig. 8 Firing Order—2.5L 4 Cylinder Engine
nish-compound applied to the rotor tip for radio in
terference noise suppression, will appear charred. IGNITION COIL
This is normal. Do not remove the charred com To perform a complete test of the ignition coil and
pound. Test the spring for insufficient tension. Re its circuitry, refer to the DRB II diagnostic scan tool.
place a rotor that displays any of these adverse
conditions.
J IGNITION SYSTEMS 80-11
Fig. 9 Firing Order—4.0L 6 Cylinder Engine Fig. 11 Ignition Coil—Typical

INSUFFICIENT If the secondary coil cable shows any signs of dam
age, it should be replaced with a new cable and new
terminal. Carbon tracking on the old cable can cause
arcing and the failure of a new ignition coil.
ENGINE COOLANT TEMPERATURE SENSOR TEST

the following:
The sensor is installed in the thermostat housing
(Fig. 12).
(1) Disconnect wire harness connector from sensor
(Fig. 12).
(2) Test the resistance of the sensor with a high in
put impedance (digital) volt-ohmmeter. The resis
tance should be less than 1340 ohms at normal
engine operating idle temperature. For resistance
values, refer to the Sensor Resistance chart. Replace
the sensor if it is not within the range of resistance
Fig. 10 Rotor Inspection—Typical specified in the chart.
Also refer to the appropriate Powertrain Diagnostics (3) Test continuity of the wire harness. This is
Procedures manual. To test the coil only, refer to the done between Powertrain Control Module (PCM)
following: wire harness connector terminal-2 and the sensor
The ignition coil (Fig. 11) is designed to operate connector terminal. Also check continuity between
without an external ballast resistor. wire harness terminal-4 to the sensor connector ter
minal. Repair the wire harness if an open circuit is
Inspect the ignition coil for arcing. Test the coil ac
indicated.
cording to coil tester manufacturer's instructions.
Test the coil primary and secondary resistance. Re
place any coil that does not meet specifications. Refer
IGNITION SECONDARY CIRCUIT DIAGNOSIS
to the Ignition Coil Resistance chart. CHECKING FOR SPARK
If the ignition coil is being replaced, the secondary
spark plug cable must also be checked. Replace cable CAUTION: When disconnecting a high voltage cable
if it has been burned or damaged. from a spark plug or from the distributor cap, twist
Arcing at the tower will carbonize the cable nipple, the rubber boot slightly (1/2 turn) to break it loose.
which if it is connected to a new ignition coil, will Grasp the boot (not the cable) and pull it off with a
cause the coil to fail. steady, even force.
IGNITION COIL RESISTANCE
PRIMARY RESISTANCE SECONDARY RESISTANCE
COIL (MANUFACTURER) 21-27°C (70-80°F) 2 1 - 2 7 ° C (70-80°F)
Diamond 0 . 9 7 - 1.18 O h m s 11,300- 15,300 O h m s
Toyodenso 0.95- 1.20 Ohms 1,300- 13,300 O h m s

„__ , —J
J918D2
ble terminal approximately 12 mm (1/2 in.) from a

THERMOSTAT good engine ground (Fig. 13).
HOUSING
J9114-9 CHECK HERE IGNITION

FOR SPARK COIL 918D-18
Fig. 12 Coolant Temperature Sensor—Typical
SENSOR RESISTANCE (OHMS) Fig. 13 Checking for Spark—Typical
WARNING: B E V E R Y C A R E F U L W H E N T H E ENGINE
IS CRANKING. DO NOT P U T Y O U R HANDS N E A R
TEMPERATURE RESISTANCE (OHMS)
T H E P U L L E Y S , B E L T S OR T H E F A N . DO N O T
W E A R L O O S E F I T T I N G CLOTHING.
C F MIN MAX
(2) Rotate (crank) the engine with the starter mo
-40 -40 291,490 381,710 tor and observe the cable terminal for a steady arc. If
-20 -4 85,850 108,390 steady arcing does not occur, inspect the secondary
-10 14 49,250 61,430
0 32 29,330 35,990 coil cable. Refer to Spark Plug Cables in this group.
10 50 17,990 21,810 Also inspect the distributor cap and rotor for cracks
20 68 11,370 13,610 or burn marks. Repair as necessary. If steady arcing
25 77 9,120 10,880 occurs, connect ignition coil cable to the distributor
30 86 7,370 8,750
40 104 4,900 5,750 cap.
50 122 3,330 3,880 (3) Remove a cable from one spark plug.
60 140 2,310 2,670 (4) Using insulated pliers, hold the cable terminal
70 158 1,630 1,870 approximately 12 mm (1/2 in.) from the engine cylin
80 176 1,170 1,340
90 194 860 970 der head or block while rotating the engine with the
100 212 640 720 starter motor. Observe the spark plug cable terminal
110 230 480 540 for an arc. If steady arcing occurs, it can be expected
120 248 370 410 that the ignition secondary system is operating cor
rectly. If steady arcing occurs at the spark plug ca
J928D-4 bles, but the engine will not start, connect the DRB
(1) Disconnect the ignition coil secondary cable II diagnostic scan tool. Refer to the Powertrain Diag
from center tower of the distributor cap. Hold the ca- nostic Procedures service manual.
FAILURE TO START TEST • If voltage is at near battery voltage and drops to

To prevent unnecessary diagnostic time and wrong zero after 1-2 seconds of cranking, check the cam
test results, the previous Checking For Spark test shaft " position sensor-to-powertrain control module
should be performed prior to this test. circuit. Refer to On-Board Diagnostics in Group 14,
Fuel Systems.
WARNING: S E T PARKING BRAKE OR BLOCK T H E • If voltage remains at near battery voltage during
DRIVE W H E E L S B E F O R E PROCEEDING W I T H T H I S the entire 5 seconds, turn the key off. Remove the
TEST. 60-way connector (Fig. 16) from the powertrain con
trol module (PCM). Check 60-way connector for any
(1) Unplug the ignition coil harness connector at spread terminals.
the coil (Fig. 14).
OOOOOOOOOO
oooooooooo 11 20
ôoooooo£|| ^ 5 i ? i oooooooo£
ôooooooooo •OOOOOOOOOO
CONNECTOR
TERMINAL SIDE
SHOWN J908D-42
Fig. 16 PCM 60-Way Connector

(5) Remove test lead from the coil positive termi
nal. Connect an 18 gauge jumper wire between the
battery positive terminal and the coil positive termi
nal.
114-21
(6) Make the special jumper shown in Figure 17.
Using the jumper, momentarily ground terminal-19
Fig, 14 Coil Harness Connector—Typical
of the 60-way connector. A spark should be generated
(2) Connect a set of small jumper wires (18 gauge at the coil cable when the ground is removed.
or smaller) between the ignition coil and coil electri
CAPACITOR CONNECT T H I S -
cal connector (Fig. 15).
CLIP T O COIL
IGNITION COIL COIL C O N N E C T O R NEGATIVE
GROUND
THIS
CLIP
ALLIGATOR CLIP RB1003

VOLT METER
Fig. 17 Special Jumper Ground-to-Coil Negative
Terminal
(7) If spark is generated, replace the powertrain
control module (PCM).
J928D-13 (8) If spark is not seen, use the special jumper to
ground the coil negative terminal directly.
Fig, 15 Coil Terminals—Typical
(9) If spark is produced, repair wiring harness for
(3) Determine that sufficient battery voltage (12.4 an open condition.
volts) is present for the starting and ignition sys (10) If spark is not produced, replace the ignition
tems. coil.
(4) Crank the engine for 5 seconds while monitor
ing the voltage at the coil positive terminal: IGNITION TIMING
• If the voltage remains near zero during the entire Base (initial) ignition timing is NOT adjustable
period of cranking, refer to On-Board Diagnostics in on any of the 2.5L 4 cylinder or 4.0L 6 cylinder
Group 14, Fuel Systems. Check the powertrain con engines. Do not attempt to adjust ignition timing
trol module and auto shut down relay. by rotating the distributor.
Do not attempt to modify the distributor hous the sensor from the engine for testing. For resistance
ing to get distributor rotation. Distributor posi values, refer to the Sensor Resistance chart. Replace
tion will have no effect on ignition timing. the sensor if it is not within the range of resistance
All ignition timing functions are controlled by the specified in the chart.
powertrain control module (PCM). Refer to On-Board SENSOR RESISTANCE (OHMS)
Diagnostics in the Multi-Port Fuel Injection—Gen
eral Diagnosis section of Group 14, Fuel Systems for
more information. Also refer to the appropriate Pow TEMPERATURE RESISTANCE (OHMS)
ertrain Diagnostics Procedures service manual for
operation of the DRB II Scan Tool. C F MIN MAX
INTAKE MANIFOLD CHARGE AIR TEMPERATURE -40 -40 291,490 381,710

SENSOR TEST -20 -4 85,850 108,390
To perform a complete test of this sensor and its -10 14 49,250 61,430
circuitry, refer to the DRB II diagnostic scan tool. 0 32 29,330 35,990
10 50 17,990 21,810
Also refer to the appropriate Powertrain Diagnostics 20 68 11,370 13,610
Procedures manual. To test the sensor only, refer to 25 77 9,120 10,880
the following: 30 86 7,370 8,750
(1) Disconnect the wire harness connector from the 40 104 4,900 5,750
sensor (Figs. 18 or 19). 50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
110 230 480 540
120 248 370 410
J928D-4
(3) Test the resistance of the wire harness. This is
done between the Powertrain Control Module (PCM)
wire harness connector terminal-21 and the sensor
connector terminal. Also check continuity between
terminal-4 to the sensor connector terminal. Repair
the wire harness as necessary if the resistance is
greater than 1 ohm.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Fig. 18 Air Temperature Sensor—2.5L Engine
TEST
the following:
The MAP sensor is located on the cowl panel near
the rear of the engine cylinder head (valve) cover
(Fig. 20).
(1) Inspect the sensor vacuum hose connections at the
throttle body and sensor (Fig. 20). Repair as necessary.
CAUTION: When testing the sensor, be sure that

the harness wires are not damaged by the test
meter probes.
(2) Test the sensor output voltage at the sensor con

nector between terminals A and B as marked on the
Fig. 19 Air Temperature Sensor—4.0L Engine sensor body (Fig. 21). This is done with the ignition
(2) Test the resistance of the sensor with a input switch ON and the engine OFF. Output voltage should
impedance (digital) volt-ohmmeter. Do not remove be 4-to-5 volts. The voltage should drop to 1.5-to-2.1
nection. If the ground connection is good, replace the

VACUUM
CONNEQTON PCM. If terminal-4 has a short circuit to 12 volts,
correct this condition before replacing the PCM.
POWERTRAIN CONTROL MODULE (PCM)

The PCM (formerly called the SBEC or engine con
troller) is located in the engine compartment behind
the windshield washer fluid bottle on YJ models
(Fig. 22). It is located in the engine compartment
next to the air cleaner on XJ models (Fig. 23).
BRAKE
MASTER
CYLINDER
J9114-10
Fig, 20 MAP Sensor—Typical
60-WAY
PCM CONNECTOR
(LOCATED
BEHIND
WASHER
FLUID
RESERVOIR) J9314-141
Fig. 22 PCM Location—YJ Models

PCM
A. Ground
B . Output Voltage
C. 5 Volts
J8914-91
Fig. 21 MAP Sensor Test—Typical

volts with a hot, neutral idle speed condition.
(3) Test Powertrain Control Module (PCM) termi
nal-1 for the same voltage described above to verify
the wire harness condition. Repair as necessary.
(4) Test sensor supply voltage at sensor connector
between terminals A and C with the ignition ON. Fig, 23 PCM Location-XJ Models
The voltage should be approximately 5 volts (±0.5V).
The ignition system is controlled by the PCM.
Five volts (±0.5V) should also be at terminal-6 of the
corresponding Powertrain Control Module (PCM)
wire harness connector. Repair or replace the wire
harness as necessary. this group.
(5) Test the sensor ground circuit at sensor connec For diagnostics, refer to the appropriate Powertrain
tor terminal-A and PCM connector terminal-4. Re Diagnostic Procedures service manual for operation
pair the wire harness if necessary. of the DRB II scan tool.
(6) Test the sensor ground circuit at the PCM con
nector between terminal-4 and terminal-11 with an SPARK PLUGS
ohmmeter. If the ohmmeter indicates an open circuit, For spark plug removal, cleaning, gap adjustment
inspect for a defective sensor ground connection. Re and installation, refer to the Component Removal/In
fer to Group 8W, Wiring for location of ground con stallation section of this group.
Faulty carbon and/or gas fouled plugs generally COLD FOULING/CARBON FOULING
cause hard starting, but they will clean up at higher Cold fouling is sometimes referred to as carbon
engine speeds. Faulty plugs can be identified in a fouling. The deposits that cause cold fouling are ba
number of ways: poor fuel economy, power loss, de sically carbon (Fig. 24). A dry, black deposit on one
crease in engine speed, hard starting and, in general, or two plugs in a set may be caused by sticking
poor engine performance. valves or defective spark plug cables. Cold (carbon)
Remove the spark plugs and examine them for fouling of the entire set of spark plugs may be caused
burned electrodes and fouled, cracked or broken por by a clogged air filter or repeated short operating
celain insulators. Keep plugs arranged in the order times (short trips).
in which they were removed from the engine. An iso
lated plug displaying an abnormal condition indi ELECTRODE GAP BRIDGING
cates that a problem exists in the corresponding Electrode gap bridging may be traced to loose deposits
cylinder. Replace spark plugs at the intervals recom in the combustion chamber. These deposits accumulate
mended in the maintenance chart in Group 0, Lubri on the spark plugs during continuous stop-and-go driv
cation and Maintenance. ing. When the engine is suddenly subjected to a high
Spark plugs that have low mileage may be cleaned torque load, deposits partially liquefy and bridge the
and reused if not otherwise defective. Refer to the gap between electrodes (Fig. 25). This short circuits the
following Spark Plug Condition section of this group. electrodes. Spark plugs with electrode gap bridging can
be cleaned using standard procedures.
CONDITION
GROUND
ELECTRODE
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 24). There will not be evidence of electrode
burning. Gap growth will not average more than ap
proximately 0.025 mm (.001 in) per 1600 km (1000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.
NORMAL D R Y BLACK COLD (CARBON) FOULING
\ DEPOSITS \ \
J908D-11
Fig. 25 Electrode Gap Bridging

8CAWENGER DEPOSITS
Fuel scavenger deposits may be either white or yellow
(Fig. 26). They may appear to be harmful, but this is a
normal condition caused by chemical additives in cer
tain fuels. These additives are designed to change the
chemical nature of deposits and decrease spark plug
misfire tendencies. Notice that accumulation on the
ground electrode and shell area may be heavy, but the
deposits are easily removed. Spark plugs with scavenger
J908D-15
deposits can be considered normal in condition and can
Fig. 24 Normal Operation and Cold (Carbon) Fouling be cleaned using standard procedures.
Some fuel refiners in several areas of the United CHIPPED ELECTRODE INSULATOR
States have introduced a manganese additive (MMT) A chipped electrode insulator usually results from
for unleaded fuel. During combustion, fuel with bending the center electrode while adjusting the
MMT causes the entire tip of the spark plug to be spark plug electrode gap. Under certain conditions,
coated with a rust colored deposit. This rust color can
severe detonation can also separate the insulator
be misdiagnosed as being caused by coolant in the
from the center electrode (Fig. 27). Spark plugs with
combustion chamber. Spark plug performance is not
this condition must be replaced.
affected by MMT deposits.
GROUND GROUND
ELECTRODE ELECTRODE
COVERED
CENTER —
ELECTRODE
J908D-12
Fig. 26 Scavenger Deposits

GROUND
J908D-13 J908D-16
Fig. 27 Chipped Electrode Insulator Fig, 29 Spark Plug Overheating

PREIGNITION DAMAGE SPARK PLUG SECONDARY CABLES
Preignition damage is usually caused by excessive com
bustion chamber temperature. The center electrode dis TESTING
solves first and the ground electrode dissolves somewhat Spark plug cables are sometimes referred to as sec
latter (Fig. 28). Insulators appear relatively deposit free. ondary ignition cables or secondary wires. The cables
Determine if the spark plug has the correct heat range transfer electrical current from the distributor to in
rating for the engine. Determine if ignition timing is dividual spark plugs at each cylinder. The spark plug
over advanced, or if other operating conditions are caus cables are of nonmetallic construction and have a
ing engine overheating. (The heat range rating refers to built in resistance. The cables provide suppression of
the operating temperature of a particular type spark radio frequency emissions from the ignition system.
plug. Spark plugs are designed to operate within specific Check the high-tension cable connections for good
temperature ranges. This depends upon the thickness contact at the ignition coil, distributor cap towers
and length of the center electrodes porcelain insulator.) and spark plugs. Terminals should be fully seated.
The terminals and spark plug covers should be in
SPARK PLUG OWERHEATING good condition. Terminals should fit tightly to the ig
Overheating is indicated by a white or gray center nition coil, distributor cap and spark plugs. The
electrode insulator that also appears blistered (Fig. spark plug cover (boot) of the cable should fit tight
29). The increase in electrode gap will be consider around the spark plug insulator. Loose cable connec
ably in excess of 0.001 inch per 1000 miles of opera tions can cause corrosion and increase resistance, re
tion. This suggests that a plug with a cooler heat sulting in shorter cable service life.
range rating should be used. Over advanced ignition Clean the high tension cables with a cloth moist
timing, detonation and cooling system malfunctions ened with a nonflammable solvent and wipe dry.
can also cause spark plug overheating. Check for brittle or cracked insulation.
When testing secondary cables for damage with an THROTTLE POSITION SENSOR TEST
oscilloscope, follow the instructions of the equipment To perform a complete test of this sensor and its
manufacturer. circuitry, refer to the DRB II diagnostic scan tool.
If an oscilloscope is not available, spark plug cables Also refer to the appropriate Powertrain Diagnostics
may be tested as follows; Procedures manual. To test the sensor only, refer to
the following:
CAUTION; Do not leave any one spark plug cable dis The throttle position sensor can be tested with a
connected for longer than necessary during testing. digital voltmeter. The center terminal of the sensor
T h i s may cause possible heat damage to the catalytic connector is the output terminal (Figs. 30 or 31).
converter. Total test time must not exceed ten minutes.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire length
of all spark plug cables. If cables are cracked or punc
tured, there will be a noticeable spark jump from the
damaged area to the test probe. The cable running from
the ignition coil to the distributor cap can be checked in
the same manner. Cracked, damaged or faulty cables
should be replaced with resistance type cable. This can
be identified by the words ELECTRONIC SUPPRES
SION printed on the cable jacket.
Use an ohmmeter to test for open circuits, exces
sive resistance or loose terminals. Remove the dis
tributor cap from the distributor. Do not remove
cables from cap. Remove cable from spark plug.
Connect ohmmeter to spark plug terminal end of ca
ble and to corresponding electrode in distributor cap.
Resistance should be 250 to 1000 Ohms per inch of
cable. If not, remove cable from distributor cap tower
and connect ohmmeter to the terminal ends of cable.
If resistance is not within specifications as found in
the Spark Plug Cable Resistance chart, replace the
cable. Test all spark plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
To test ignition coil-to-distributor cap cable, do not Fig. 31 Sensor—4.0L Engine

remove the cable from the cap. Connect ohmmeter to With the ignition key in the ON position and en
rotor button (center contact) of distributor cap and gine not running, check the sensor output voltage at
terminal at ignition coil end of cable. If resistance is the center terminal wire of the connector. Check this
not within specifications as found in the Spark Plug at idle (throttle plate closed) and at wide open throt
Cable Resistance chart, remove the cable from the tle (WOT). At idle, sensor output voltage should be
distributor cap. Connect the ohmmeter to the termi greater than 200 millivolts. At wide open throttle,
nal ends of the cable. If resistance is not within spec sensor output voltage must be less than 4.8 volts.
ifications as found in the Spark Plug Cable The output voltage should increase gradually as the
Resistance chart, replace the cable. Inspect the igni throttle plate is slowly opened from idle to WOT.
tion coil tower for cracks, burns or corrosion.
For removal and installation of spark plug cables, OXYGEN SENSOR TESTS
refer to Spark Plug Secondary Cables in the Compo For diagnosis, removal or installation, refer to
nent Removal/Installation section. Group 14, Fuel Systems in this manual.
IGNITION SYSTEMS 8D - 19
J
COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Automatic Shut Down (ASD) Relay 19 Intake Manifold Charge Air Temperature Sensor . 26
Camshaft Position Sensor 19 Manifold Absolute Pressure (MAP) Sensor 26
Crankshaft Position Sensor . 20 Oxygen ( 0 ) Sensor
2 27
Distributor 22 Powertrain Control Module (PCM) . . . . . . . . . . . . 27
Engine Coolant Temperature Sensor 21 Spark Plug Secondary Cables 28
General Information 19 Spark Plugs 27
Ignition Coil . 25 Throttle Position Sensor ( T P S ) 28
GENERAL INFORMATION
This section of the group, Component Removal/In
stallation, will discuss the removal and installation
of ignition system components.
For basic ignition system diagnostics and service
adjustments, refer to the Diagnostics/Service Proce
dures section of this group.
For system operation and component identification,
refer to the Component Identification/System Opera

The ASD relay is installed in the Power Distribu
tion Center (PDC) (Fig. 1). Relay location is printed
on the PDC cover.
Fig. 2 PDC- YJ Models
CAMSHAFT POSITION SENSOR
tributor.
REMOVAL
(1) Remove the distributor. Refer to Distributor
Removal.
(2) Remove the distributor rotor.
CAUTION: Do not position the distributor in a vise

when removing or installing the drive gear roll pin.
Support the distributor with wooden blocks.
J9114-91
(3) Mark the position of the gear and the shaft in
line with the roll pin. The gear MUST be installed
Fig. 1 PDC-XJ Models back to its original position on the distributor shaft.
(4) Using a small pin punch and hammer, remove
REMOVAL the distributor gear roll (spring) pin (Fig. 3).
(1) Remove the PDC cover. (5) Lightly tap the end of the distributor shaft un
(2) Remove the relay by lifting straight up. til distributor gear and thrust washer are removed.
(6) Slide the distributor shaft out of the distributor
INSTALLATION housing.
(1) Push the relay into the connector. (7) Remove the camshaft position sensor mounting
(2) Install the relay cover. screw and positioning arm (Fig. 4).
(8) Slide the wire harness grommet out of the dis
tributor housing. Remove the camshaft position sen
sor.
8D - 2 0 IGNITION SYSTEMS J
transmission bellhousing at the left/rear side of the

engine block (Figs. 5, 6 or 7).
On 2.5L and 4.0L engines (except YJ models with
automatic transmissions) the sensor is attached with
two bolts.
On YJ models with a 4.0L engine and automatic
transmission, the sensor uses a single slotted hole to
adjust its depth. A paper/cardboard type spacer with
self-adhesive (Fig. 7) is attached to the bottom of the
sensor to set this depth. After the engine has been
started (and after sensor installation), this temporary
spacer will be sheared off. New factory replacement
sensors are equipped with this spacer. If the original
sensor is to be reinstalled, such as with transmission
and/or flywheel removal, a new spacer MUST be in
stalled.
Fig. 3 Distributor Gear—Removal/Installation
SENSOR HARNESS
Fig. 5 Crankshaft Position Sensor—2.5L Engine
SENSOR RETAINING SCREW J938D-11
Fig. 4 Camshaft Position Sensor

INSTALLATION
(1) Position the camshaft position sensor in the
distributor housing. Place the wire harness grommet
into the opening in the distributor housing.
(2) Install retaining arm and retaining screw.
(3) Install distributor shaft into distributor hous
ing. Make sure the upper thrust washer is installed
on the shaft.
(4) Position thrust washer and drive gear on dis
tributor shaft.
(5) Note the previous CAUTION and install dis Fig. 6 Crankshaft Position Sensor—4.0L Engine—All
tributor drive gear roll pin. <
'
Except YJ models With Automatic Transmission
(6) Install rotor.
(7) Install distributor. REMOVAL—ALL ENGINES
(1) Near the rear of the intake manifold, discon
CRANKSHAFT POSITION SENSOR nect the pigtail harness (on the sensor) from the
The crankshaft position sensor is mounted in the main electrical harness.
J IGNITION SYSTEMS 8D - 2 1
installed. If spacer is not installed, sensor will be

damaged when engine is started.
(2) Position sensor to transmission bellhousing and
install mounting bolt finger tight.
(3) Gently seat (push down) the sensor until it con
tacts the outer edge of the flywheel.
(4) Tighten sensor mounting bolt (Fig. 7) to 17-
to-21 N-m (13-to-16 ft. lbs.) torque.
(5) Connect the electrical connector to sensor.
(6) Install the clip to sensor wire harness.
(7) Install clip over fuel rail mounting stud. Install
clip mounting nut.
ENGINE COOLANT TEMPERATURE SENSOR

WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV
ING THE COOLANT TEMPERATURE SENSOR. RE
FER TO GROUP 7, COOLING.
Fig. 7 Crankshaft Position Sensor—4.0L Engine—YJ REMOVAL

models With Automatic Transmission The sensor is installed in the thermostat housing
(Fig. 8).
(2) Remove the nut holding sensor wire clip to fuel
rail mounting stud.
(3) Remove the sensor mounting bolt(s).
(4) Remove the sensor.
(5) Remove clip from sensor wire harness.
INSTALLATION-ALL EXCEPT YJ MODELS

WITH 4.0L ENGINE AND AUTOMATIC
TRANSMISSION
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the two sensor mounting
bolts to 19 N*m (14 ft. lbs.) torque.
CAUTION: The two bolts used to secure the sensor

to the transmission are specially machined to cor
rectly space the unit to the flywheel Do not attempt
to install any other bolts. Fig. 8 Coolant Temperature Sensor—Typical
(1) Drain cooling system until the coolant level is
(3) Connect the electrical connector to the sensor.
below the cylinder head. For cooling system draining,
(4) Install clip on sensor wire harness.
refer to Group 7, Cooling.
(5) Install clip over fuel rail mounting stud. Install (2) Disconnect the coolant temperature sensor wire
clip mounting nut. connector.
(3) Remove the sensor from the thermostat hous
INSTALLA TION— YJ MODELS WITH 4»0L
ing (Fig. 8).
ENGINE AND AUTOMATIC TRANSMISSION
(1) Be sure the paper/cardboard spacer (Fig. 7) has INSTALLATION
been installed to the bottom of the new sensor. (1) Install coolant temperature sensor into the
If original sensor is being reinstalled (such as with thermostat housing. Tighten to 28 N*m (21 ft. lbs.)
transmission or flywheel removal), clean bottom of torque.
the sensor before installation. Obtain a new spacer (2) Connect the wire connector.
and remove the paper backing. Install the self-adhe (3) Fill the cooling system. Refer to group 7, Cool
sive side to bottom of sensor. This spacer MUST be ing System.
8D - 2 2 IGNITION SYSTEMS J
DISTRIBUTOR INSTALL A TION-2.5L ENGINE

All distributors contain an internal oil seal that
prevents oil from entering the distributor housing. ENGINE NOT ROTATED AFTER RE10WAL
The seal is not serviceable. This procedure assumes that the engine was not ro
The camshaft position sensor is located in the dis tated with distributor out of engine.
tributor on all engines (Fig. 9). (1) Clean the distributor mounting hole area of the
Refer to Fig. 9 for an exploded view of the distrib engine block.
utor. (2) Install a new distributor-to-engine block gas
ket.
CAP CAMSHAFT POSITION
SENSOR
There is a fork on the distributor housing where
the housing seats against the engine block. The slot
in the fork aligns with the distributor holddown bolt
hole in the engine block. The distributor is correctly
installed when the rotor is correctly positioned. This
is with the slot in the fork aligned with the hold-
down bolt hole in the cylinder block. Because of the
fork on the distributor housing, initial ignition tim
ing is not adjustable (the distributor cannot be rotat
ed).
(3) Position the distributor shaft in the cylinder
block. If the engine was not rotated while the distrib
utor was removed, perform the following:
• Align the rotor tip with the scribe mark on the
distributor housing during removal. Turn the rotor
approximately 1/8-turn counterclockwise past the
scribe mark.
CAUTION; Be sure that the distributor shaft fully

engages into the oil pump drive gear shaft. It may
be necessary to slightly rotate (bump) the engine.
T h i s i s done while applying downward hand force
on the distributor body. It should fully engage the
distributor shaft with the oil pump drive gear shaft.
• Slide the distributor shaft down into the engine.
It may be necessary to move the rotor and shaft
(slightly) to engage the distributor shaft with the slot
in the oil pump shaft. The same may have to be done
Fig. 9 Distributor—2.5U4.0L Engines—Typical
to engage the distributor gear with the camshaft
HEMOVAL-2 5L B ENGINE gear. However, the rotor should align with the scribe
(1) Disconnect the negative battery cable at the mark when the distributor shaft is down in place.
battery. • Install the distributor holddown clamp and bolt.
(2) Disconnect coil secondary cable at coil. Tighten the bolt to 23 N-m (17 ft. lbs.) torque.
(3) Remove distributor cap from distributor (2 (4) Install the distributor cap (with the ignition ca
screws). Do not remove cables from cap. bles) on the distributor housing (Fig. 10). Tighten
(4) Disconnect the distributor wiring harness from distributor cap holddown screws to 3 N*m (26 in. lbs.)
the main engine harness. torque.
(5) Scribe a mark on the distributor housing in (5) Connect the distributor wiring harness to the
line with the tip of the rotor. Note the position of the main engine harness.
rotor and distributor housing. This is in relation to
the surrounding engine components as reference CAUTION: Do not puncture the spark plug cables or
points for installing the distributor. boots to make the connection. Use proper adapters.
(6) Remove the distributor holddown bolt and (6) Connect battery cable to battery.
clamp. /
(7) Remove the distributor from engine oy lifting ENGINE ROTATED AFTER REiOWAL
straight up. Remove and discard old distributor-to- There is a fork on the distributor housing where
engine block gasket. Note that the rotor will rotate the housing seats against the engine block. The slot
slightly in a counterclockwise direction while lifting in the fork aligns with the hole for the distributor
up the distributor. Note this position after removal. holddown bolt in the engine block. The distributor is
4 IGNITION SYSTEMS 80 - 23
• With the distributor cap removed, install the dis

tributor with the rotor located just past the 2 o'clock
position (Fig. 12).
F R O N T FACE
Fig. 10 Spark Plug Cable Positions—2.5L Engine

correctly installed when the rotor is correctly posi
tioned. This is when the slot in the fork is aligned
with the hole for the distributor holddown bolt in the
cylinder block. Because of the fork on the distributor
housing, initial ignition timing is not adjustable (the
—I
distributor cannot be rotated).
J918D-13
(1) If the engine was rotated while the distributor
was removed, it will be necessary to establish timing Fig. 12 Distributor Installation—2.5L Engine
according to following procedure:
• When distributor is fully engaged in its correct lo
• Remove the No. 1 spark plug. Hold a finger over
cation, the rotor should be just past the 3 o'clock po
the spark plug hole and rotate the engine until com
sition (Fig. 13).
pression pressure is felt. Slowly continue to rotate
the engine. Do this until the timing index on vibra
tion damper pulley aligns with top dead center (TDC)
mark (0 degree) on timing degree scale. Always ro
tate the engine in direction of normal rotation. Do
not turn the engine backward to align the timing
marks.
• Using a flat blade screwdriver, rotate the oil pump
gear. Do this to position the gear slot on the oil
pump shaft slightly before the 11 o'clock position
(Fig. 11).
F R O N T FACE
ROTOR POSITION
W H E N PROPERLY INSTALLED
J918D-14
Fig. 13 Distributor Rotor Position—2.5L Engine

OIL P U M P • Install the distributor holddown clamp and bolt.
GEAR SLOT Tighten the holddown bolt to 23 N*m (17 ft. lbs.)
J918D-12 torque.
Fig. 11 Align Oil Pump Gear Slot—2.5L Engine
CAUTION; If the distributor cap i s incorrectly posi (5) Turn the engine in a clockwise direction until
tioned on distributor housing, the cap or rotor may the rotor is approaching the scribe mark on the dis
be damaged when engine is started. tributor housing. Then slowly turn the engine until
the timing mark on the crankshaft vibration damper
(2) Install the distributor cap (with ignition cables) lines up with zero on the front cover timing scale
on the distributor housing. Be sure that the cap fits (Fig. 15).
securely on rim of the distributor housing. The timing mark is on the edge of the vibra
(3) Connect the distributor wiring harness to the tion damper closest to the engine front cover.
main engine harness.
CAUTION: Do not puncture the spark plug cables or

boots to make the connection. Use proper adapters.
REMOVAL-4.0L ENGINE
The distributor used in the 4.0L engine contains an
internal oil seal that prevents oil from entering the
distributor housing. The seal is not serviceable.
tributor on all engines (Fig. 9).
Refer to figure 9 for an exploded view of the dis
tributor.
(1) Disconnect the negative battery cable at bat
tery.
(2) On XJ models equipped with A/C, remove the
electrical cooling fan and shroud assembly from the
radiator. This will provide room to turn the engine CRANKSHAFT
with a socket and ratchet using the vibration damper VIBRATION DAMPER
TIMING MARK
bolt.
(3) Scribe a mark on the distributor housing. Do J898D-14
this below the left side of (past) the number one
spark plug cable post of the distributor cap. This will Fig. 15 Align Timing Marks
be used as a reference for #1 cylinder firing position (6) Align the trailing edge of the rotor blade with
(Fig. 14). the scribe mark on the distributor housing (Fig. 16).
(7) Remove the distributor holddown bolt and
CAMSHAFT POSITION
J938D-15 SENSOR HARNESS
PULSE
Fig. 14 Mark Distributor Housing RING J938D-9
(4) Remove the distributor cap from distributor (2
screws). Fig. 16 Align Rotor Trailing Edge With Scribe Mark
clamp.
(8) Remove the distributor from the engine by lift
ing straight up. Remove and discard old distributor-
to-engine block gasket. Note that the rotor will
rotate slightly in a counterclockwise direction while
lifting up the distributor. Note this position after re
moval.
INSTALLA TfOM—4*0L ENGINE

(1) Clean the distributor mounting area of the cyl
inder block.
(2) Install a replacement distributor-to-engine
block gasket.
(3) Using a flat blade screwdriver, turn the oil
pump gear shaft. Do this until the slot is slightly
past the 11 o'clock position (Fig. 17).
The oil pump shaft is located down in the distribu
tor hole.
HOLD-DOWN
CLAMP BOLT HOLE J898D-17
FRONT
OF Fig. 18 Distributor Installation—Typical
ENGINE
L I
11 O'CLOCK
OIL P U M P
GEAR S H A F T J898D-16
Fig. 17 Align Oil Pump Gear Shaft—4.0L Engine

(4) Install the rotor.
(5) Without engaging the distributor gear into the
cam gear, position the distributor into the hole in the
engine block. Be sure the distributor gasket is in
stalled.
(6) Visually line up the holddown ear of the dis
tributor housing with the holddown clamp hole (Fig.
18).
(7) Turn the rotor to the 4 o'clock position (Fig.
19).
(8) Slide the distributor down into the block until Fig. 19 Rotor Alignment
it seats. Keep the holddown ear aligned to the hole
in the block. IGNITION COIL
(9) The rotor should be in the 5 o'clock position. The ignition coil is an epoxy filled type. If the coil
This is with the trailing edge of rotor blade lined up is replaced, it must be replaced with the same type.
with scribe mark on distributor housing (number one
spark plug cable post location). REMOVAL
(10) Install the distributor holddown clamp bolt The ignition coil is mounted to the right side of the
and tighten to 23 N*m (17 ft. lbs.) torque. engine block next to the distributor (Fig. 20).
(11) Install the distributor cap and connect the dis (1) Disconnect the ignition coil secondary cable
tributor electrical connector. from ignition coil (Fig. 20).
(12) Install electrical cooling fan and shroud if ap (2) Disconnect engine harness connector from igni
plicable. tion coil.
(13) Connect battery cable to battery.
8D - 2S IGNITION SYSTEMS J
Fig. 20 Ignition Coil—Typical Fig. 22 Air Temperature Sensor—4.0L Engine

(3) Remove ignition coil mounting screws. Remove INSTALLATION
coil. (1) Install the air temperature sensor into the in
take manifold. Tighten the sensor to 13 JNhn (10 ft.
INSTALLATION lbs.) torque.
(1) Install ignition coil to bracket on cylinder block (2) Connect the electrical connector to the sensor.
with mounting screws.
(2) Connect engine harness connector to coil. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
(3) Connect ignition coil cable to ignition coil. The MAP sensor is located on the dash panel near
INTAKE MANIFOLD CHARGE AIR TEMPERATURE (Fig. 23).
SENSOR
VACUUM
REMOVAL CONNECTION
The intake manifold charge air temperature sensor
is installed into the intake manifold plenum (Figs. 21
or 22).
J9114-10

THROTTLE REMOVAL
POSITION
(1) Disconnect the MAP sensor electrical connector
SENSOR
(Fig. 23).
J9314-140
(2) Disconnect the MAP sensor vacuum supply
hose (Fig. 23).
Fig. 21 Air Temperature Sensor—2.5L Engine (3) Remove the MAP sensor mounting nuts and re
(1) Disconnect the electrical connector from the move MAP sensor.
sensor.
(2) Remove the sensor from the intake manifold. INSTALLATION
(1) Install MAP sensor to dash panel and secure
with mounting nuts.
(2) Install the MAP sensor vacuum supply hose.
IGNITION SYSTEMS 8D - 27
(3) Connect the MA? sensor electrical connector.
OXYGEN (0 ) SENSOR
2
For diagnostics and removal/installation proce

dures, refer to Group 14, Fuel Systems, in this man
ual.
The PCM was formerly referred to as the SBEC or
engine controller.
XJ MODELS
On XJ models, the PCM is located in the engine
compartment next to the air cleaner (Fig. 24).
PCM
Fig. 2 5 PCM Location-YJ Models

(3) Loosen 60-way connector mounting screw until
connector can be disengaged from PCM.
(4) Pull 60-way connector straight back from PCM.
(5) Remove PCM mounting screws.
(6) Remove PCM from vehicle.
INSTALLATION
(1) Check the pins in the PCM 60-way electrical
connector for damage. Repair as necessary.
(2) Install PCM. Tighten mounting screws to 1
N*m (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting screw to 4 Nrm (35 in. lbs.)
torque.
REM0¥AL (4) Connect battery cable to battery.
(1) Disconnect negative battery cable at battery. (5) Install washer fluid reservoir.
(2) Loosen 60-way connector mounting screw until
connector can be disengaged from PCM. SPARK PLUGS
(3) Pull 60-way connector straight back from PCM.
(4) Remove PCM mounting screws. PLUG REMOVAL
(5) Remove PCM from vehicle. (1) Always remove spark plug or ignition coil ca
bles by grasping at the cable boot. Turn the cable
INSTALLATION boot 1/2 turn and pull straight back in a steady mo
(1) Check the pins in the PCM 60-way electrical tion. Never pull directly on the cable. Internal dam
connector for damage. Repair as necessary. age to cable will result.
(2) Install PCM. Tighten mounting screws to 1 (2) Prior to removing the spark plug, spray com
#
N m (9 in. lbs.) torque. pressed air around the spark plug hole and the area
(3) Engage 60-way connector into PCM. Tighten around the spark plug. This will help prevent foreign
connector mounting screw to 4 N®m (35 in. lbs.) material from entering the combustion chamber.
torque. (3) Remove the spark plug using a quality socket
(4) Connect battery cable to battery. with a rubber or foam insert.
(4) Inspect the spark plug condition. Refer to
YJ MODELS Spark Plugs in the Diagnostics/Service Procedures
On YJ models, the PCM is located in the engine section of this group.
compartment behind the windshield washer fluid res
ervoir (Fig. 25). PLUG CLEANING
The plugs may be cleaned using commercially
REH0WAL available spark plug cleaning equipment. After
(1) Disconnect negative battery cable at battery. cleaning, file the center electrode flat with a small
(2) Remove windshield washer fluid reservoir. point file or jewelers file before adjusting gap.
PLUG GAP ADJUSTMENT the rubber boot slightly (1/2 turn) to break it loose.
Check the spark plug gap with a gap gauge tool. If Grasp the boot (not the cable) and pull it off with a
the gap is not correct, adjust it by bending the steady, even force.
ground electrode (Fig. 26). Never attempt to adjust
Install cables into the proper engine cylinder firing
the gap by bending the center electrode.
order (Figs. 27 or 28).
SPARK PLUG GAP
• 2.5L Engine Spark Plug Gap: .89 mm (.035 in).
• 4.0L Engine Spark Plug Gap: .89 mm (.035 in).
Fig. 27 Engine Firing Order—2.5L Engine
J908D-10
Fig. 26 Setting Spark Plug Gap—Typical

PLUG INSTALLATION
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion. This may re
sult in a change in the spark plug gap.
When replacing the spark plug and ignition coil ca
bles, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables Fig. 28 Engine Firing Order—4.0L Engine
properly can cause the radio to reproduce ignition When replacing the spark plug and coil cables,
noise. It could cause cross ignition of the spark plugs, route the cables correctly and secure in the proper
or short circuit the cables to ground. retainers. Failure to route the cables properly can
(1) Start the spark plug into the cylinder head by cause the radio to reproduce ignition noise. It could
hand to avoid cross threading. also cause cross ignition of the plugs, or short circuit
(2) Tighten the spark plugs to 35-41 N*m (26-30 ft. the cables to ground.
lbs.) torque. When installing new cables, make sure a positive
(3) Install spark plug cables over spark plugs. connection is made. A snap should be felt when a
good connection is made between the plug cable and
SPARK PLUG SECONDARY CABLES the distributor cap tower.
CAUTION: When disconnecting a high voltage cable THROTTLE POSITION SENSOR (TPS)
from a spark plug or from the distributor cap, twist For diagnostics and removal/installation proce
dures, refer to Group 14, Fuel Systems, in this man
ual.
4 IGNITION SYSTEMS 8 0 - 29
IGNITION SWITCH—ALL MODELS
INDEX
page page
General Information 29 Ignition Switch Removal 29
Ignition Switch Installation/Adjustment 30 Ignition Switch Testing 29
GENERAL INFORMATION V I E W FROM L O W E R PART O F S W I T C H

The ignition switch is mounted (under the instru
IGNITION
ment panel) on the lower section of the steering col SWITCH
SUDER
BAR
umn. The headlamp dimmer switch is mounted
beside the ignition switch (Fig. 1). Both of these
switches (ignition and dimmer) share the same
mounting screws.
The switch is connected to the ignition key lock as
sembly by a remote actuator rod. This remote actua
tor rod fits into an access hole on the bottom of the
ignition switch (Fig. 2).
IGNITION
SWITCH
ADJUSTMENT
HOLE
ACTUATOR
ROD
(FROM KEY
SWITCH) J928D-5
Fig. 2 Ignition Switch/Remote Actuator

Rod—Typical
Before removing dimmer switch, tape the two
remote control actuator rods (ignition switch
and dimmer) to the steering column. This will
prevent accidental disengagement from the up
per part of the steering column.
(5) Remove the ignition switch-to-steering column
attaching screws.
DIMMER (6) Disengage the ignition switch from the remote
J8919-116
SWITCH
actuator rod by lifting straight up. Remove switch
from steering column.
Fi9. 11gnition Switch/Headlamp Dimmer (7) Remove wiring from switch as follows:
Switch—Typical
Two electrical connectors are used to connect all
IGNITION SWITCH REMOVAL wiring to the ignition switch. One of the connectors
(1) Disconnect the negative battery cable at the is installed (interlocked) over the top of the other
battery. connector. Remove wiring from switch by disconnect
(2) X J models: Remove the lower instrument panel ing the (black) harness connector first and then the
trim assembly. Y J models: Remove the windshield other connector. Remove the switch from the vehicle.
wiper intermittent control module and its bracket (if
equipped). IGNITION SWITCH TESTING
(3) Place the ignition key lock in ACCESSORY po To test the ignition switch circuity and continuity,
sition. proceed as follows. Place the slide bar (on the igni
(4) Remove the two headlamp dimmer switch at tion switch) (Fig. 2) into the detent position to be
taching nuts. Lift the switch from steering column tested. An ohmmeter or continuity light may be used
while disengaging actuator rod. to check switch continuity. Refer to the Ignition
Switch Continuity Tests chart for continuity tests.
Refer to (Fig. 3) for the lettered/numbered terminal IGNITION SWITCH CIRCUITRY
positions. All wiring must be disconnected from
the ignition switch before performing any conti O START
nuity testing. ON
There are five positions on the ignition switch. The O F F _ ^
0 < }
switch positions (in order) are: ACCESSORY, OFF- LOCK ,0
LOCK, OFF, ON AND START (Figs. 4 or 5). Each

position has a detent stop (except START), which is ACCOi
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 •B
04— 2
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.
IGNITION SWITCH CONTINUITY TESTS S-
!
CXI—tO— •B 3
SWITCH DETENT NORMAL CIRCUIT
POSITION CONTINUITY
START Between 1-1, B-1 and S. °i
G-l and G-2 to switch case (ground).
ON Between 1-1, A, 1-3 to B-1, B-2 and B-3.

CX O » <•
OFF Between B-1, B-2 and B-3 only.
OFF-LOCK Between B-1, B-2 and B-3 only.
ACCESS. Between A and B-2. G-

2
CASE
Note: Circuits B-1, B-2 and B-3 are commonly connected and GND
will show continuity at all times.
J928D-7
IGNITION SWITCH INSTALLATION/ADJUSTMENT

(1) Place the key lock switch in the ACCESSORY
position. IGNITION SWITCH TERMINALS
(2) Place the slider bar (in the ignition switch)
(Fig. 2) into the ACCESSORY detent position.
(3) Connect the wiring to the switch as follows: In
stall the non-black (colored) connector first and then
the black (colored) connector to the ignition switch.
3-
One connector will interlock the other connector. fey
(4) Slip the remote actuator rod into the access
hole on the switch (Fig. 2). Install the switch to the
steering column. Be careful not to move the slider
bar (on the switch) out of the ACCESSORY detent
J928D-6
position. Remove the ignition switch actuator rod se-
curing-tape from steering column. Fig. 3 Ignition Switch Terminals/Circuits
(5) Install the two ignition switch-to-steering col
umn screws finger tight. Do not tighten screws at screws. Do not allow the ignition switch to move
this time. from the ACCESSORY detent position.
(6) Adjust ignition switch as follows: (b) Tilt steering column: While holding the key
(a) Non-tilt steering column: While holding key lock switch in the ACCESSORY position, gently
lock switch in ACCESSORY position, gently slide slide the ignition switch down (away from steering
ignition switch up (towards steering wheel). This wheel) to remove slack from switch. Tighten at-
will remove slack from switch. Tighten attaching
J IGNITION SYSTEMS 8 0 - 31
taching screws. Do not allow the ignition switch to

move from the ACCESSORY detent position.
Because the ignition switch and the headlamp dim
mer switch share the same two mounting screws, one
of the screws must be removed from the ignition
switch. This must be done after the ignition switch
has been adjusted and before the dimmer switch has
been installed. Remove one screw. Do not remove
the stud/nut.
(7) Install the headlamp dimmer switch as follows:
Slip switch into actuator rod and position over the ig
nition switch. Install screws finger tight. Remove the
dimmer switch actuator rod securing-tape from steer
ing column.
(8) Adjust dimmer switch as follows: Depress the
switch slightly and insert a 3/32-inch drill bit into 8
OFF-LOCK
the adjustment hole (Fig. 1). This is done to prevent L- ACCESSORY
horizontal switch movement.
(9) Move switch toward steering wheel to remove J908D-37
any lash from switch actuator rod. Tighten dimmer Fig. 4 Detent Positions—Non-Tilt Steering Column
#
and ignition switch fasteners to 4 N m (35 in. lbs.)
torque. ACCESSORY-
(10) XJ models: Install the lower instrument panel OFF-LOCK —i
trim assembly. YJ models: Install the windshield OFF 1
wiper intermittent control module and its bracket (if ON 1
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.
Fig. 5 Detent Positions—Tilt Steering Column

SPECIFICATIONS
GENERAL INFORMATION ENGINE FIRING ORDER-2.SL ENGINE

The following specifications are published from the
latest information available at the time of publica
tion. If anything differs between the specifica ['front jg
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec
ifications, use specifications on VECI label. The
VECI label is located in the engine compartment.
TORQUE
DESCRIPTION TORQUE FIRING ORDER:

1 3 4 2
Coolant Temperature Sensor 28 N-m (21 ft. lbs.) CLOCKWISE
ROTATION
Crankshaft Position Sensor 19 N-m (15 ft. lbs.)
Distributor Hold Down Bolt 23 N-m (17 ft. lbs.)
PCM Mounting Screws 1 N-m (9 in. lbs.) J908D-6
PCM 60-Way Electrical Connector 4 N-m (35 in. lbs.)

ENGINE FIRING ORDER-4.0L ENGINE
Headlamp Dimmer Switch/Ignition
Switch Mounting Screws/Nuts 4 N-m (35 in. lbs.)
Intake Manifold Charge Air
Temperature Sensor 28 N-m (20 ft. lbs.)
Oxygen Sensor 30 N-m (22 ft. lbs.)
Spark Plugs-All Engines.... 37 N-m (27 ft. lbs.)
J938D-17
SPARK PLUGS
ENGINE PLUG ELECTRODE

TYPE GAP FIRING ORDER:
1 5 3 6 2 4
2.5L/4.0L RC12LYC 0.89 mm CLOCKWISE
(0.035 in.) ROTATION
J928D-12 J908D-7
J INSTRUMENT PANEL AND GAUGES 8E - 1
INSTRUMENT PANEL AND GAUGES

GROUP INDEX
page page
INSTRUMENT PANEL AND G A U G E S - I J ..... 1 INSTRUMENT PANEL AND GAUGES—YJ . . . . 14
INSTRUMENT PANEL AND G A U G E S - X J

CONTENTS
page page
GENERAL INFORMATION 1 INSTRUMENT CLUSTER SERVICE

INSTRUMENT CLUSTER DIAGNOSIS 3 PROCEDURES , .. 5
SPECIFICATIONS . 13
GENERAL INFORMATION
INDEX
page page
4WD Indicator . , . 2 Malfunction Indicator Lamp (Check Engine) 2
Anti-Lock Brake Indicator 2 Oil Pressure Gauge 1
Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Oil Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . 1
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . 1 Speedometer/Odometer System 2
Coolant Temperatire Indicator 1 Tachometer 1
Fuel Gauge 2 Upshift Indicator 2
Low Fuel Warning . 2 Voltmeter 1
With the ignition switch in the RUN or START po side. When oil pressure is too low, the switch closes
sition, voltage applied to the instrument cluster is providing a path to ground, and the indicator lights.
limited by the gauges fuse. The voltage applied to
the instrument cluster is applied to all the gauges COOLANT TEMPERATURE GAUGE
and indicators through the instrument cluster The coolant temperature gauge pointer position is
printed circuit. controlled by a magnetic field created by electrical
With the ignition switch in the OFF position, volt current flow through the coils within the gauge. A
age is not applied to the instrument cluster and the change in current flow will change the magnetic field
gauges do not indicate any vehicle condition. which changes the pointer position. The coolant tem
perature sensor is a thermistor that provides a differ
VOLTMETER ent electrical resistance for different temperatures of
The voltmeter measures the output of the genera the coolant. As the resistance changes, the current
tor when the engine is running. When the engine is changes and the pointer moves to a new position
not running the voltmeter measures battery voltage.
(values shown in chart).
OIL PRESSURE GAUGE
COOLANT TEMPERATURE INDICATOR
The oil pressure gauge pointer position is con
trolled by a magnetic field created by electrical cur Voltage is applied to one side of the indicator bulb
rent flow through the coils within the gauge. A and the coolant temperature switch is connected to
change in current flow will change the magnetic field the other side. When coolant temperature is too high,
which changes the pointer position. The oil pressure the switch closes providing a path to ground, and the
sender is variable resistor that changes electrical re indicator lights.
sistance with a change in oil pressure (values shown
in chart). TACHOMETER
The tachometer displays the engine speed, (RPM).
OIL PRESSURE INDICATOR With the engine running, the tachometer receives an
Voltage is applied to one side of the indicator bulb engine speed signal from the Powertrain Control
and the oil pressure switch is connected to the other Module pin 43 (values shown in Specifications chart).
8E - 2 XJ INSTRUMENT PANEL AND GAUGES J
SPEEDOMETER/ODOMETER SYSTEM BRAKE INDICATOR
The speedometer/odometer system consists of an The brake indicator warns the driver that the
electric speedometer and pushbutton reset odometer parking brake is on or that the pressure in the brake
mounted in the cluster. The system also includes the system is unequal.
wire harness from the cluster to the vehicle speed Voltage is applied through the brake indicator bulb
sensor at the transmission, and the adapter and pin to 3 switches. A path to ground for the current is
available if:
ion in the transmission. A signal is sent from a
• The brake warning switch is closed (with unequal
transmission mounted vehicle speed sensor to the
brake system pressures), or
speedometer/odometer circuitry through the wiring • The ignition switch is in START (to test the bulb),
harness. Refer to Group 21 - Transmission for select or
ing the proper pinion, and selecting and indexing the • The park brake switch is closed (with the park
proper adapter. brake on).
FUEL GAUGE ANTI-LOCK BRAKE INDICATOR

The fuel gauge pointer position is controlled by a Check Anti-lock illuminates to indicate self-check
magnetic field created by electrical current flow in process at vehicle start-up. If light remains ON af
through the coils within the gauge. A change in cur ter start-up or comes ON and stays ON at road
rent flow will change the magnetic field which speeds, it may indicate that the ABS system has de
changes the pointer position. The fuel level sender is tected a malfunction or has become inoperative.
a variable resistor that changes electrical resistance 4WD INDICATOR
depending on the level of fuel in the tank. As the re COMMAND TEAC 4WD
sistance changes, the current changes and the The part time indicator lights when the vehicle is
pointer moves to a new position (values shown in engaged in 4-wheel drive mode. Voltage is provided
chart). to one side of the indicator. A switch in the transfer
case area is connected to the other side of the indica
LOW FUEL WARNING tor. When the switch is closed, a path to ground is
The low fuel warning indicator starts to glow when provided and the indicator lights.
the fuel tank holds approximately 4 gallons. A low SELECT TEAC 4WD
fuel warning module controls when the indicator will The 4-wheel drive indicator lights when the vehicle
light. When the module senses 66.5 ohms or less is engaged in full time 4-wheel drive mode. The Part
from the fuel level sender for 10 continuous seconds, Time indicator lights when the vehicle is in a part
the indicator will light. The indicator will remain on time 4-wheel drive mode. Voltage is provided to one
side of the indicators. Switches in the transfer case
until the module senses 63.5 ohms or more from the
area are connected to the other side of the indicator.
fuel sender for 20 continuous seconds. When a switch is closed, a path to ground is provided
and the indicator lights.
UPSHIFT INDICATOR
Vehicles equipped with manual transmissions have MALFUNCTION INDICATOR LAMP (CHECK ENGINE)
an optional Up-Shift indicator lamp. The lamp is con The Malfunction Indicator lamp (Check Engine) il
trolled by the Powertrain Control Module. The lamp luminates each time the ignition key is turned on
illuminates to indicate when the driver should shift and stays on for 3 seconds as a bulb test.
to the next highest gear for best fuel economy. The If the PCM receives an incorrect signal or no signal
Powertrain Control Module will turn the lamp OFF from certain sensors or emission related systems the
after 3 to 5 seconds if the shift of gears is not per lamp is turned on (pin 32 of PCM). This is a warning
formed. The shift light will remain off until the ve that the PCM has recorded a system or sensor mal
hicle stops accelerating and is brought back to the function. In some cases when a diagnostic trouble
code is declared the PCM will go into a limp-in mode
range of shift light operation or shifted into fifth
in an attempt to keep the system operating. It sig
gear. nals an immediate need for service.
The indicator lamp is normally illuminated when The lamp also can be used to display diagnostic
the ignition switch is turned ON and it is turned trouble codes (DTC). Cycle the ignition switch on, off,
OFF when the engine is started up. The lamp will be on, off, on within 5 seconds. This will allow any trou
illuminated during engine operation according to en ble codes stored in the PCM memory to be displayed
gine speed and load. in a series of flashes representing digits.
XJ INSTRUMENT PANEL AND GAUGES 8E - 3
I N S T R U M E N T C L U S T E R DIAGNOSIS
INDEX
page page
4WD Indicator Inoperative 4 Malfunction Indicator (Check Engine) . . . . . . . . . . . 4
Anti-Lock Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Pressure Gauge Inoperative . . . . . . . . . . . . . . . 3
Brake Indicator Inoperative 4 Oil Pressure Indicator Inoperative 3
Coolant Temperature Gauge Inoperative 3 Radio/Clock Illumination 4
Coolant Temperature Indicator Inoperative . . . . . . . 3 Seat Belt Indicator 4
Fuel Gauge Inoperative . . . . . . . . . . . . . . . . . . . . . 3 Speedometer 3
Gauges and Indicators Inoperative 3
Instrument Panel Lamps 4 Tachometer Inoperative 3
Low Fuel Warning Inoperative 4 Upshift Indicator Inoperative 4
Low Washer Indicator Inoperative . . . . . . . . . . . . . 4 Voltmeter Inoperative 3
SPEEDOMETER
(1) Check for continuity in the wire between the
vehicle speed sensor and cluster connector pin A5.
(2) With the ignition switch in the ON position,
check for battery voltage across pin A8 (B + ) and pin
B2 (ground).
(3) Perform vehicle speed sensor test. Refer to the
appropriate Vehicle Diagnostics Test Procedures
Manual.
(4) If all the previous tests prove good, replace
speedometer.
GAUGES AND INDICATORS INOPERATIVE

(1) Remove and inspect Gauges fuse. Replace as re
quired.
(2) Measure resistance at instrument Cluster con
nector terminal A3. Meter should read zero ohms. If Fig. 1 Oil Pressure Sending Unit—4.0L
not, repair open to ground.
COOLANT TEMPERATURE GAUGE INOPERATIVE
VOLTMETER INOPERATIVE (1) Turn ignition switch to RUN.
(1) Turn ignition switch to RUN. Voltmeter should (2) Disconnect Coolant Temperature Sender con
read battery voltage. If not, go to step 2. nector. Needle goes to C. If not, go to step 3.
(2) Measure voltage at instrument Cluster connec (3) Touch Coolant Temperature Sender connector
tor terminal A8. Meter should read battery voltage. to ground. Needle goes to H. If OK, replace sender. If
If OK, replace meter. If not, repair open to Gauges not, repair open to gauge.
fuse.
COOLANT TEMPERATURE INDICATOR
OIL PRESSURE GAUGE INOPERATIVE INOPERATIVE
(1) Turn ignition switch to RUN. (1) Turn ignition switch to RUN.
(2) Disconnect Oil Pressure Sender connector (Fig. (2) Touch Coolant Temperature Indicator connector
1). Needle goes to H. If not, go to step 2. to ground. Lamp lights. If OK, replace switch. If bulb
(3) Touch Oil Pressure Sender connector to ground. is OK, repair open to instrument cluster connector
Needle goes to L. If OK, replace sender. If not, repair terminal A l .
open to gauge (instrument cluster connector terminal
B7). TACHOMETER INOPERATIVE
Tachometer input is from the Powertrain Control
OIL PRESSURE INDICATOR INOPERATIVE Module pin 43. Use the DRB II Scan Tool to test.
(1) Turn ignition switch to RUN.
(2) Touch Oil Pressure Switch connector to ground. FUEL GAUGE INOPERATIVE
Lamp should light. If OK, replace switch. If bulb is (1) Turn ignition switch to RUN.
OK, repair open to instrument cluster connector ter (2) Disconnect Fuel Gauge sender connector. Nee
minal B7. dle should go to E.
(3) Connect a jumper between terminal A on the MALFUNCTION INDICATOR (CHECK ENGINE)
two halves of the fuel Gauge Sender connector. The (1) Turn ignition switch to RUN.
gauge should move to F. If gauge is OK, replace (2) Jumper Powertrain Control Module terminal 2
sender. If not, go to step 4. to ground. Lamp should light. If bulb is OK, check
(4) Measure resistance of sender. Meter should for open to instrument cluster connector terminal 2.
read 105 to 5 ohms. If OK, go to step 5. If not, re
place sender. ANTI-LOCK INDICATOR
(5) Check for an open between sender connector (1) Turn ignition switch to RUN.
and gauge. If OK, replace gauge. If not, repair open (2) Jumper instrument cluster connector terminal
to gauge. 6 to ground. Lamp should light. If bulb is OK, check
wiring for an open to module. Refer to Group 5 -
LOW FUEL WARNING INOPERATIVE Brakes.
(2) Disconnect terminal Bl of the instrument clus SEAT BELT INDICATOR
ter connector. Wait at least 10 seconds. Lamp (LED) Jumper instrument cluster connector terminal 15
lights should light. If OK, replace sender. If not, re to 12 volts. Lamp should light. If not, replace bulb. If
place module. OK, check wiring for an open to buzzer module. Re
fer to Group 8U - Chime/Buzzer Warning Systems.
UPSHIFT INDICATOR INOPERATIVE
(1) Turn key to RUN. RADIO/CLOCK ILLUMINATION
(2) Ground pin 7 of connector B. Lamp should light. If With the Ignition Switch in ACCY or RUN, power
not, replace bulb. If OK, continue with step 3. comes from the Radio Fuse. It then goes through the
(3) Turn Key to OFF. Check for continuity be normally closed contacts of the Radio Illumination
tween connector B pin 2 and pin 54 of the Power- Relay to the Radio at connector terminal 11.
train Control Module. If OK, replace PCM. If not, Pulling the Headlamp switch to PARK or HEAD
repair open. energizes the Radio Illumination relay. This closes
the normally open contacts of the relay, and the
BRAKE INDICATOR INOPERATIVE brightness for the radio display is controlled by the
(1) Turn ignition switch to RUN. Apply parking Headlamp switch rheostat. The back-lighting for the
brake, Brake Warning Switch connector unplugged. radio is also controlled by the Headlamp rheostat
(2) Jumper Brake Warning Switch connector ter through radio connector terminal 10.
minal B to ground. Lamp should light. If bulb is OK, Refer to Group 8F - Audio Systems for Radio Illu
repair open to indicator. mination Relay diagnosis.
(3) Turn key to OFF. Measure resistance between
Brake Warning Switch connector terminal A and INSTRUMENT PANEL LAMPS
ground. Meter should read zero ohms. If ok, check Voltage is applied at all times from the 40 amp
switch and/or brake system. If not, repair open to Maxi fuse (located in the Power Distribution Center)
Park Brake Switch ground. through the Park Lps fuse to the headlamp switch.
The circuit continues through the Inst Lps fuse to
4WD INDICATOR INOPERATIVE the individual instrument panel lamps to ground.
(1) Apply parking brake, Engine RUNNING, vehi Lamp brightness is controlled by turning the head
cle in 4WD Lock or 4WD. lamp switch knob.
(2) Unplug switch and touch harness side of wire
to ground. Lamp should light. If OK, check switch DIAGNOSIS
operation, replace if bad. If bulb is OK, repair open (1) Turn parking lamps ON.
to indicator. (2) Check Park Lps fuse. Replace as required.
(3) Check Inst Lps fuse. Replace as required.
LOW WASHER INDICATOR INOPERATIVE (4) Measure voltage at battery side of Inst Lps fuse
(1) Turn ignition switch to RUN. with Rheostat turned counterclockwise to clockwise
(2) Jumper 12 volts to fluid level switch connector (LO to HI). Meter should read zero - battery voltage.
terminal B. Lamp should light. If not, go to step 3. If not, replace headlamp switch.
(3) Measure resistance between terminal B and (5) Measure resistance at ground side of Inst Lps
ground. Meter should read zero ohms. If not, repair fuse with Parking lamps OFF. Meter should read al
open to bulb. If OK, go to step 4. most zero ohms (except bulb filament). If not, repair
(4) Measure voltage at fluid level switch connector open to ground. If zero ohms, 12 volt supply wire
terminal A. Meter should read battery voltage. If from fuse is shorted to ground, repair short.
OK, replace switch. If not, repair open to fuse.
J XJ INSTRUMENT PANEL AND IAUGES 8E - i
INSTRUMENT C L U S T E R SERVICE P R O C E D U R E S
INDEX
page page
Gauge Replacement—Instrument Cluster Removed . . 5 Removed 6
Gear Selector Indicator Replacement—Instrument Speedometer Replacement—Instrument Cluster
Cluster Removed . . . . . . . . . . . . . . . . . . . . . . . . 7 Removed . 5
Instrument Cluster Replacement 5 Tachometer Replacement—Instrument Cluster
Instrument Panel Replacement 8 Removed 5
Printed Circuit Replacement—Instrument Cluster
INSTRUMENT CLUSTER REPLACEMENT I N S T R U M E N T CLUSTER

(1) Disconnect negative cable from battery. ATTACHING SCREWS
(2) Remove 4 instrument panel bezel attaching
screws and remove instrument panel bezel. Bezel is
snap fit at locations shown (Fig. 2).
BEZEL SNAP FIT
ATTACHING LOCATION
N
SCREWS
SWITCH
LOCATIONS J928E-21
HOUSING J928E-22
Fig. 2 instrument Bezel Removal/Installation—XJ Fig. 3 Instrument Cluster Removal/Installation—XJ

(3) Remove cigar lighter housing attaching screws SPEEDOMETER REPLACEMENT-INSTRUMENT
(Fig. 3).
CLUSTER REMOVED
(4) Remove switch housing attaching screws (if (1) Remove cluster lens and gauge bezel. If
equipped). equipped with trip odometer, gently pull knob of trip
(5) Remove instrument panel cluster attaching odometer push pin.
screws. (2) Remove 6 attaching screws from rear of cluster
(6) Pull out cluster assembly far enough to discon housing.
nect 2 multiple plugs and remove instrument cluster. (3) Remove speedometer assembly including circuit
To install cluster, reverse the removal procedures. board.
(4) Install speedometer. Install attaching screws.
GAUGE REPLACEMENT-INSTRUMENT CLUSTER
(5) Install gauge bezel and lens.
REMOVED
(6) Install knob on trip odometer push pin.
(1) Remove cluster lens and gauge bezel (Fig. 4). If
equipped with trip odometer, gently pull knob of trip TACHOMETER REPLACEMENT-INSTRUMENT
odometer push pin. CLUSTER REMOVED
(2) Remove gauge attaching screws from rear of (1) Remove cluster lens and gauge bezel. If
mounting bezel. Remove gauge from front. equipped with trip odometer, gently pull knob of trip
(3) Install gauge. Install attaching screws. odometer push pin.
(4) Install cluster bezel and lens. (2) Remove 3 attaching screws from rear of cluster
(5) Install knob on trip odometer push pin. housing.
J928E-33
Fig. 4 Instrument Cluster

(3) Remove tachometer assembly including circuit There is a separate printed circuit f o r the
board. warning lights that is removed by removing the
(4) Install tachometer. Install attaching screws. lamp sockets.
(5) Install gauge bezel and lens.
(6) Install knob on trip odometer push pin. ASSEMBLY
(1) Position printed circuit, including connector, on
PRINTED CIRCUIT REPLACEMENT—INSTRUMENT the back of the instrument panel cluster.
CLUSTER REMOVED (2) Remove gauge bezel and lens.
(3) Hold components in place and install screws.
DISASSEMBLY (4) Install lamp sockets.
(1) Remove all attaching screws for gauges, ta (5) Pivot connector up and install retaining strap.
chometer, and speedometer that are contacting (6) Install gauge bezel and cluster lens.
printed circuit (Fig. 5).
(2) Remove screw holding the cluster connector re GEAR SELECTOR INDICATOR
taining strap to bezel. Remove strap and pivot con REPLACEMENT-INSTRUMENT CLUSTER
nector down (Figs. 6 and 7). REMOVED
(3) Remove lamp sockets from circuit board. (1) Remove screws from rear of mounting bezel
(4) Remove printed circuit including connector. holding Fuel Gauge in place.
4 XJ INSTRUMENT PANEL AND GAUGES 8E - 7"
ENGINE OIL PRESSURE COOLANT T E M P E R A T U R E

GAUGE ATTACHING GAUGE ATTACHING SCREWS
SCREWS
LOW FUEL WARNING

VOLTMETER MODULE ATTACHING FUEL
ATTACHING SCREWS GAUGE
SCREWS ATTACHING
1. I L L U M I N A T I O N LAMPS
SCREWS
2. R I G H T T U R N INDICATOR L A M P
3. HI-BEAM INDICATOR L A M P
4. L E F T T U R N INDICATOR L A M P
J928E-19
Fig. 5 Printed Circuit Removal/Installation
CONNECTOR
RETAINING
STRAP
CONNECTOR
J918E-15
Fig. 6 Cluster Connector Retaining Strap Fig. 7 Printed Circuit And Cluster Connector
(2) Remove 2 screws holding gear selector indica (5) To adjust indicator, place transmission in Park.
tor (Fig. 8). (6) Align pointer on indicator with Park position.
(3) Pull cable and clip through hole in the mount (7) Install clip to steering column shroud.
ing bezel and remove indicator. (8) Move transmission shift lever to check proper
(4) Install indicator and cluster. alignment.
• ash receiver
• lower instrument panel (Fig. 10)
• cluster bezel
• cluster assembly
• clock (if equipped)
• radio and heater control panel
• instrument panel switches
• headlamp switch
• antenna connector
• blower motor resistors
• ground lead
• disconnect glove box light
• defroster cowl panel
Remove driver's side heat/AC outlet to gain ac
cess to left hand defroster cowl panel retaining
clip to aid in removal (Fig. 11).
• instrument panel attaching bolts
Fig. 8 Gear Selector Indicator
• steering column attaching bolts
INSTRUMENT PANEL REPLACEMENT (Fig. S) • instrument panel assembly
(1) Disconnect negative cable from battery. The instrument panel wiring harness is at
(2) Remove: tached to the back of the instrument panel as
• Parking brake release handle sembly and must be installed correctly for
• lower heat/AC duct below steering column installation.
J928E-34
Fig. 9 Instrument Panel Exploded View

XJ INSTRUMENT PANEL AND GAUGES 8E - 9
LOWER INSTRUMENT
PANEL J9Q8E-6
Fig. 10 Lower Instrument Panel Removal/Installation

(3) To install instrument panel, position instru
ment panel assembly on side mounting bolts (Fig.
12).
(4) Route wiring harnesses and secure instrument J898E-36
panel assembly mounting points.
(5) Reverse the removal procedures. Fig. 11 Driver's Side Defroster Cowl Retaining Clip
DEFROSTER HEATER DEFROSTER

TUBE VACUUM TUBE
HARNESS
MOUNTING
BOLTS
MOUNTING)
BOLTS
ENGINE HARNESS-
INSTRUMENT HEATER CONTROL

PANEL BOWDEN WIRE J918E-17
Fig. 12 Instrument Panel Installation

CONNECTOR B
INDICATORS
GND
TERMINAL NAME
IGN
1 A LOW WASHER
2 B CHECK E N G I N E
C D E FT 1
1)1)4) j 3
4
5
6
B
C
IGN
IGN
IGN
CHECK A N T I L O C K
7 D UP SHIFT
8 E BRAKE
9 F SECURITY
10 F BATT
11 G FULL TIME
12 H PART TIME
13 1 MAINT REQD
14 1 IGN
6 6 6 6 6 6 6 6 6 6 6 6 15 J SEAT BELT
6 6 6 6
1 2 3 4 8 9 10 11 12 13 14 15 16 16 GND
5 6 7
J918E-11
INSTRUMENT CLUSTERS
J XJ INSTRUMENT PANEL AND GAUGES 8E - 11
LOW LINE CLUSTER
CANADA
CONNECTOR A
J XJ INSTRUMENT PANEL AND GAUGES 8E - 13
SPECIFICATIONS
INSTRUMENT CLUSTER GAUGES
O I L P R E S S U R E G A U G E CALIBRATION VOLTMETER CALIBRATION

POINTER POSITION RESISTANCE YOLTAGE I N P U T POINTER POSITION
0 psi Grad. ± 2° 1 ohm 12V 12V Grad. ± 6 °
40 psi Grad. ± V/i° 46 ohms 16V 16V Grad. ± 3 °
80 psi Grad. ± 3° 87 ohms
TACHOMETER C A L I B R A T I O N
TEMPERATURE GAUGE CALIBRATION
ENGINE FREQUENCY INDICATION
POINTER POSITION RESISTANCE 4&6 66.7 HZ 2000 RPM ± 140
IGtPF Grad. ± V h ° 1365 ohms CYLINDER 166.7 HZ 5000 RPM ± 140
220°F Grad. ± V h ° 93.5 ohms
260°FGrad. ± 2'A 0
55.1 ohms SPEEDOMETER CALIBRATION
ENGINE FREQUENCY INDICATION
-1.5
FUEL GAUGE CALIBRATION 44.4 HZ 20 mph + 4 5
POINTER POSITION RESISTANCE

4&6 -.3
Empty Grad. + 0 ° —4° 105 ohm 122.2 HZ 55 mph
CYLINDER
+3.3
1/2 Full Grad. ± 3Vi° 33 ohms
166.5 HZ 7 5 m p h
Full Grad. + 6° - 0 * 5 ohms +13

J918E-9X
8E - 14 YJ INSTRUMENT PANEL AND GAUGES
INSTRUMENT PANEL AND G A U G E S - Y J

CONTENTS
page page
GAUGE PACKAGE DIAGNOSIS 22 INSTRUMENT CLUSTER DIAGNOSIS 14
GAUGE PACKAGE GENERAL INFORMATION . 22 INSTRUMENT CLUSTER SERVICE
GAUGE PACKAGE SERVICE PROCEDURES . . 24 PROCEDURES 17
GENERAL INFORMATION 14 SPECIFICATIONS 27
GENERAL INFORMATION
SPEEDOMETER/ODOMETER SYSTEM engine speed signal from the Powertrain Control
The speedometer/odometer system consists of an Module pin 43 (values shown in Specifications chart).
electric speedometer and pushbutton reset odometer
mounted in the cluster. The system also includes the INDICATOR LAMPS
wire harness from the cluster to the vehicle speed The Brake, Upshift (2.5L with 5 speed transmis
sensor at the transmission, and the adapter and pin sion except California), and Malfunction Indicator
ion in the transmission. A signal is sent from a (Check Engine), lamps are located in the indicator
transmission mounted vehicle speed sensor to the lamp panel above the steering column. The lamps
speedometer/odometer circuitry through the wiring share a common battery feed connection through the
harness. Refer to Group 21 - Transmission for select
ignition switch and fuse #9.
ing the proper pinion, and selecting and indexing the
The turn signals, high beam indicator, seat belt re
proper adapter.
minder, hazard lamp, master lighting and illumina
TACHOMETER tion bulbs are supplied battery voltage through
The tachometer displays the engine speed, (RPM). various switches and share a common ground.
With the engine running, the tachometer receives an
INSTRUMENT CLUSTER DIAGNOSIS

INDEX
PAGE PAGE
BRAKE INDICATOR 1 6 SEAT BELT R E M I N D E R 1 6

DIAGNOSING—AIL L A M P S O U T . 1 4 SPEEDOMETER 1 4
INSTRUMENT PANEL ILLUMINATION L A M P S . . . . . . . . . . 1 6 TACHOMETER 1 4
MALFUNCTION INDICATOR L A M P ( C H E C K E N G I N E ) . . . . . 1 6 UPSHIFT INDICATOR . 1 6
SPEEDOMETER TACHOMETER
(1) Raise vehicle. (1) Tachometer input is from the Powertrain Con
(2) Disconnect the vehicle speed sensor connector. trol Module (PCM) pin 43. Use the DRB II Scan Tool
(3) Connect a voltmeter between the black wire to perform actuator test. If Ok, continue with step 2.
pin of the connector and ground. If not, replace PCM.
(4) Turn the ignition key to the RUN position. (2) Check for continuity between cluster connector
(5) Check for approximately 5 volts. If OK, per pin 12 and PCM pin 43. If OK, replace tachometer. If
form vehicle speed sensor test. Refer to the appropri not, repair open circuit.
ate Powertrain Diagnostics Procedures Manual. If
DIAGNOSING—ALL LAMPS OUT
not OK, continue with step 6.
(1) Inspect fuse #9. Replace as required.
(6) Turn ignition key to OFF position. (2) Measure voltage at instrument cluster connec
(7) Check continuity between vehicle speed sensor tor terminal 20. Meter should read zero ohms. If not,
connector and terminal 13 of instrument cluster con repair open to ground.
nector. If OK, replace speedometer. If not OK, repair
open circuit.
SP PULSE
LOGIC G N D
T A PULSE
HJ O IGN
O
Iffl 00BQ0
BRAKE Q >0
CO
l o> o
CHECK ANTILOCK
UPSHIFT
I
[
C
> CHECK E N G I N E
5 IO o
IGN
CO o-
O •HI
3D
L.H. T U R N
R.H. T U R N
HIGH BEAM 13
S E A T BELT
>
HAZARD Z
ILLUMI
o
o
S o- -©- >
M A S T E R LIGHTING o
m
00
GND
CO
00 80-
8E - 16 YJ INSTRUMENT PANEL AND GAUGES J
UPSHIFT INDICATOR emission related systems the lamp is turned on (pin

Vehicles equipped with manual transmissions have 32 of PCM). This is a warning that the PCM has re
an optional Up-Shift indicator lamp. The lamp is con corded a system or sensor malfunction. In some cases
trolled by the PCM. The lamp illuminates to indicate when a diagnostic fault is declared the PCM will go
when the driver should shift to the next highest gear into a limp-in mode in an attempt to keep the system
for best fuel economy. The PCM will turn the lamp operating. It signals an immediate need for service.
OFF after 3 to 5 seconds if the shift of gears is not The lamp also can be used to display diagnostic
performed. The shift light will remain off until the trouble codes (DTC). Cycle the ignition switch on, off,
vehicle stops accelerating and is brought back to the on, off, on within 5 seconds. This will allow any
range of shift light operation or shifted into fifth DTC's stored in the PCM memory to be displayed in
gear. a series of flashes representing digits.
The indicator lamp is normally illuminated when (1) Turn key to RUN.
the ignition switch is turned ON and it is turned (2) Ground pin 4 of cluster connector. Lamp should
OFF when the engine is started up. The lamp will be light. If not, replace bulb. If OK, continue with step
illuminated during engine operation according to en 3.
gine speed and load. (3) Turn key to OFF. Check for continuity between
(1) Turn key to RUN. cluster connector pin 4 and PCM cavity 32. If OK, re
(2) Ground pin 2 of cluster connector. Lamp should place PCM. If not, repair open.
light. If not, replace bulb. If OK, continue with step
3. SEAT BELT REMINDER
(3) Turn key to OFF. Check for continuity between Apply 12 volts to terminal 16 of cluster connector.
cluster connector pin 2 and pin 54 of the PCM. If not, Lamp should light. If not, replace bulb. If OK, check
repair open. If OK, refer to DRB II Scan Tool actua wiring for an open to buzzer module. Refer to Group
tor test of upshift indicator. 8U - Chime/Buzzer Warning Systems.
BRAKE INDICATOR INSTRUMENT PANEL ILLUMINATION LAMPS

The brake indicator is a dual function lamp. It will The instrument panel illumination lamps share
indicate an unequal pressure condition in the brake two common connections. There is a splice after fuse
hydraulic system and it also will indicate when the #10 that connects the lamps to battery feed. There is
parking brake is engaged. Separate switches are also a splice that connects all lamps to ground. Be
used for each indicator lamp function. A switch cause they share these common connection points in
mounted on the brake pedal assembly will close a a parallel circuit, the illumination lamps will all
ground circuit whenever the parking brakes are ap come on at the same time. It also means one or more
plied. A second switch is installed in the brake hy lamps can be out without affecting the operation of
draulic lines near the master cylinder. If the switch the other lamps.
is balanced by equal pressure on both ends of the On the battery side of the circuit, the headlamp
switch valve, the valve remains centered and the switch illumination rheostat/switch and panel lamps
lamp remains off. If the valve is shifted by unequal fuse receive battery feed in series from the park/tail
pressure between the front or rear brake hydraulic fuse. In the park lamp position, the headlamp switch
systems, the lamp circuit is connected to ground. To completes the circuit from the park/tail fuse to the il
make sure the brake lamp is functional before the lumination rheostat/switch and panel lamps fuse.
vehicle is driven, it is illuminated through a ground The illumination rheostat contains a variable resis
circuit when the ignition switch is turned to the tor that allows the driver to vary illumination inten
START position. sity from off to full brightness.
(2) Ground pin 1 of the cluster connector, Lamp DIAGNOSIS
should light. If not, replace bulb. If OK, continue (1) Turn parking lamps ON.
with step 3. (2) Check fuse #10. Replace as required.
(3) Turn key to OFF. Check for continuity to Park (3) Measure voltage at battery side of fuse #10
Brake switch and Brake warning switch. with Rheostat turned counterclockwise to clockwise
(LO to HI). Meter should read zero - battery voltage.
MALFUNCTION INDICATOR LAMP (CHECK ENGINE) If not, replace headlamp switch.
The Malfunction Indicator lamp (Check Engine) il (4) Measure resistance at ground side of fuse #10
luminates each time the ignition key is turned on with Parking lamps OFF. Meter should read almost
and stays on for 3 seconds as a bulb test. zero ohms (except bulb filament). If not, repair open
If Powertrain Control Module (PCM) receives an to ground. If zero ohms, 12 volt supply wire from fuse
incorrect signal or no signal from certain sensors or is shorted to ground, repair short.
J YJ INSTRUMENT PANEL AND GAUGES 8E - 17
INSTRUMENT C L U S T E R SERVICE PROCEDURES
INDEX
page page
Headlamp Switch/Illumination Rheostat 20 Printed Circuit Replacement . . 20
Indicator Bezel Replacement 19 Rear Defogger/Fog Lamp/Rear Wiper Switches . . 21
Instrument Cluster Bulb Replacement 19 Speedometer Replacement . . . . . . . . . . . . . . . . . 17
Instrument Cluster Replacement 17 Tachometer Replacement . . . . . . . . . . . . . . . . . . 17
INSTRUMENT CLUSTER REPLACEMENT REMOVE CLUSTER

(1) Remove 6 shroud screws (Fig. 1). ' SCREWS
•MOUNTING*
SCREWS
J928E-23
Fig. 2 Cluster Removal

(4) Remove 3 screws and tachometer lens (Fig. 4).
(5) Gently pry up clip to release lens from bezel
(Fig. 5).
* MOUNTING/ (6) Remove 3 screws from rear of housing (Fig. 6).
INSTRUMENT
SHROUD SCREWS Remove tachometer.
J908K-12 (7) Install tachometer with 3 screws.
Fig. 1 instrument Shroud Removal/Installation (8) Snap lens into place.
(9) Install lens with 3 screws.
(2) Slide shroud toward steering wheel, (10) To install the cluster, reverse the removal pro
(3) Remove 3 screws holding right side switch cedures.
panel (Fig. 2).
(4) Remove 3 screws holding left side switch bezel. SPEEDOMETER REPLACEMENT
(5) Remove 2 screws holding cluster in place. (1) Disconnect negative cable from battery.
(6) Lift up top of cluster. Roll cluster out between (2) Remove instrumentation shroud (Fig. 1). Refer
steering column and instrument panel far enough to to Instrumentation Shroud Replacement.
reach connector located behind tachometer. (3) Remove cluster as described in cluster replace
(7) Disconnect cluster connector and remove clus ment.
ter (Fig. 3). (4) Remove 3 screws and speedometer lens (Fig. 7).
(8) To install cluster, reverse the removal proce (5) Gently pry up clip to release lens from bezel
dures. (Fig. 5).
(6) Remove 3 screws from rear of housing (Fig. 8).
TACHOMETER REPLACEMENT Remove speedometer.
(1) Disconnect negative cable from battery. (7) Install speedometer with 3 screws.
(2) Remove instrumentation shroud (Fig. 1). Refer (8) Snap lens into place.
to Instrumentation Shroud Replacement. (9) Install lens with 3 screws.
(3) Remove cluster as described in cluster replace (10) To install the cluster, reverse the removal pro
ment. cedures.
J928E-26
Fig. 3 instrument Cluster

YJ INSTRUMENT PANEL ANO I A U G E S 8E - 19
LENS
J928E-14
J928E-24
Fig. 6 Tachometer Removal/Installation
Fig. 4 Tachometer Lens INDICATOR
BEZEL
RETAINING INSTRUMENT
CLUSTER B E Z E L LENS
CLIP
LENS
J928E-25
J928E-17
Fig. 7 Speedometer Lens
Fig. 5 Cluster Lens Retaining Clip (9) Reverse removal procedures to install new
INDICATOR BEZEL REPLACEMENT panel and bezel.
(1) Disconnect negative cable from battery. (10) Install speedometer and tachometer lenses.
(2) Remove instrumentation shroud (Fig. 1). (11) Install shroud.
(3) Remove 3 screws and tachometer lens (Fig. 4). (12) Install negative cable to battery.
(4) Gently pry up clip to release lens from bezel
(Fig. 5). INSTRUMENT CLUSTER BULB REPLACEMENT
(5) Remove 3 screws and speedometer lens (Fig. 7). Refer to Printed Circuit Replacement for bulb re
(6) Gently pry up clip to release lens from bezel placement.
(Fig. 5).
(7) Remove indicator bezel (Fig. 3).
(8) Lift indicator panel off locating pins.
20 XJ INSTRUMENT PANEL AND GAUGES
PRINTED CIRCUIT REPLACEMENT

Remove cluster as described in cluster replacement.
DISASSEMBLY
(1) Remove all attaching screws for speedometer
and tachometer (Fig. 9).
(2) Remove 2 screws holding cluster connector re
taining plate to housing (Fig. 10).
(3) To remove plate, slide it toward bottom of hous
ing (Fig. 11).
(4) Remove lamp sockets from circuit board.
(5) Remove printed circuit including connector.
ASSEMBLY
(1) Position printed circuit, including connector, on
the back of instrument panel cluster.
(2) Remove gauge bezel and lens.
(3) Hold components in place and install screws.
(4) Install lamp sockets.
(5) Pivot connector up and install retaining plate.
-J928E-20
(6) Install gauge bezel and cluster lens.
Fig. 8 Speedometer Removal/Installation HEADLAMP SWITCH/ILLUMINATION RHEOSTAT
(2) Remove instrument cluster shroud (Fig. 1).
(3) Remove 3 screws holding switch bezel (Fig. 12).
(4) Remove 2 screws from the appropriate switch
to be replaced (Fig. 13).
SPEEDOMETER TACHOMETER
ATTACHING S C R E W S ATTACHING S C R E W S
1. Illumination Lamps 6. High Beam Indicator Lamp

2. Right Turn Indicator Lamp 7. Lett Turn Indicator Lamp
3. Master Lighting 8. Check Anti Lock
4. Seat Belt Indicator Lamp 9. Hazard Indicator Lamp
5. Parking Brake Indicator Lamp 10. Upshift Indicator Lamp
11. Cneck Engine
J938E-50
Fig. 9 Printed Circuit Removal/Installation

YJ INSTRUMENT PANEL AND GAUGES 8E - 21
PRINTED CIRCUIT
C O N N E C T O R ATTACH ING-
SCREWS
J928E-30
Fig. 12 Left Hand Instrument Panel Switch Bezel.
ILLUMINATION
RHEOSTAT M O U N T I N G
J928E-15 SCREWS
Fig. 10 Printed Circuit Connector Attaching Screws
J928E-31
Fig. 13 Headlamp Switch/Illumination Rheostat
PRINTED CIRCUIT
^CONNECTOR RETAINING
J928E-16
PLATE
Fig. 11 Cluster Connector Retaining Strap

(5) Remove the switch connector.
(6) Reverse the removal procedures for installa
tion.
REAR DEFOGGER/FOG LAMP/REAR WIPER -J928E-32-
SWITCHES Fig. 14 Right Hand Instrument Panel Switch Bezel

(2) Remove instrument cluster shroud (Fig. 1). (5) Release tabs holding switch and remove switch.
(3) Remove 3 screws holding switch bezel (Fig. 14). (6) Reverse the removal procedures for installa
tion.
(4) Remove the switch connector.
8E - 22 YJ INSTRUMENT PANEL AND GAUGES J
G A U G E P A C K A G E G E N E R A L INFORMATION
The gauge package contains 4 gauges and the 4 across the battery feed and ground.
wheel drive indicator. The gauges have a common The remaining gauges - oil pressure, fuel and cool
battery feed from fuse #9 and ignition switch. Al ant temperature - are connected to individual sender
though they have separate power sources, the 4 units. Variable resistors in the senders will change
gauges share a common ground connection. the amount of current allowed to flow through the
The voltmeter indicates electrical system voltage. gauge coils. As current flow through the coils varies,
When the engine is not running, the voltage regis the position of the indicator needle also will vary.
tered is from the battery. After the engine is started, The 4 gauges are connected to battery feed, ground
charging system voltage is indicated. In the gauge and the sender units through a printed circuit
package, the voltmeter forms a parallel connection mounted on the back of the gauge housing.
G A U G E P A C K A G E DIAGNOSIS
ALL GAUGES INOPERATIVE (Fig. 15) FUEL GAUGE SENDER
(1) Check the fuse #9. Replace as required. (1) Turn ignition switch to RUN.
(2) Turn ignition switch to RUN and measure volt (2) Separate fuel gauge sender connector from fuel
age at battery side of fuse #9. Meter should read bat gauge sender near tank.
tery voltage. If not, repair open from ignition switch. (3) Ground the center wire of the body harness
(3) Unplug Gauge Package connector from gauge side of the connector (Tan/BK). The gauge should
package. read at low end of scale. If ok, check sending unit
(4) Turn ignition switch to OFF and measure resis (step 4). If not, check circuit between connector and
tance from Instrument Cluster connector terminals 1
gauge. Repair as required. If circuit is OK, replace
and 13 to a clean chassis ground. Meter should read
zero ohms. If not, repair open to ground. gauge.
(5) Turn ignition switch to RUN and measure volt (4) Turn ignition switch to OFF.
age at instrument cluster connector terminals 2 and (5) Measure resistance from fuel gauge sender con
12. Meter should read battery voltage. If not, repair nector center terminal to a clean chassis ground.
open from fuse panel. Meter readings should correspond to shown in Speci
fications. If not OK replace sender. If Ok, repair open
ONE GAUGE INOPERATIVE from fuel gauge sender connector to ground.
Does not apply to voltmeter.
PRINTED CIRCUIT
OIL PRESSURE SENDER (1) Turn ignition switch to RUN.
(1) Turn ignition switch to RUN. (2) Unplug gauge package connector from gauge
(2) Unplug oil pressure sender connector from oil
package.
pressure sender.
(3) Measure resistance from gauge package termi
(3) Touch connector to engine block (ground).
nal 12 (fuel and coolant temp gauge) or from termi
Gauge should read at low end of scale.
(4) When connector is NOT touching ground (open nal 2 (voltmeter and oil pressure gauge) to gauge
circuit) gauge should read at high end of scale. If OK battery terminal. Meter should read zero ohms. If
replace sensor. If not, proceed with step 5. not, replace/repair printed circuit.
(5) Check circuit between sensor and gauge for an (4) Measure resistance from gauge package termi
open. Repair as required. If wiring is OK, replace nal 13 (fuel and coolant temp gauge) or from termi
gauge. nal 1 (voltmeter and oil pressure gauge) to gauge
ground terminal. Meter should read zero ohms. If
COOLANT TEMPERATURE SENDER not, replace/repair printed circuit. If zero ohms, re
(1) Turn ignition switch to RUN. place gauge.
(2) Unplug coolant temperature sender connector
from coolant temperature sender. GAUGE CALIBRATION VALUES
(3) Touch connector to engine block (ground). Use the charts in Specifications. The calibration of
Gauge should read at high end of scale. the gauge can be checked. If the indicator needle is
(4) When connector is NOT touching ground (open not in the correct position, replace the gauge.
circuit) gauge should read at low end of scale. If OK
replace sensor. If not, proceed with step 5. 4WD INDICATOR
(5) Check circuit between sensor and gauge for an The 4WD indicator lamp circuit is completed by
open. Repair as required. If wiring is OK, replace the Command Trac switch located below the battery.
gauge.
if YJ INSTRUMENT PANEL AND GAUGES 8E - 23
U.S.A.
CANADA
J928E-6
Fig. 15 Gauge Package Wiring Schematic—YJ

8E - 24 YJ INSTRUMENT PANEL AND GAUIES
GAUGE P A C K A G E SERVICE PROCEDURES

PRINTED CIRCUIT REMOVAL GAUGE
CLUSTER
DISASSEMBLY
(1) Remove all gauge attaching screws (Fig. 16).
(2) Remove screw holding the cluster connector re
taining plate to the housing (Fig. 16).
(3) To remove the plate, slide it toward the bottom
of the housing (Fig. 17).
(4) Remove the lamp sockets from the circuit
board.
(5) Remove the printed circuit including the con
nector.
ASSEMBLY
(1) Position the printed circuit, including connec
tor, on the back of the instrument panel cluster.
(2) Remove gauge bezel and lens.
(3) Hold the components in place and install the
screws. P R I N T E D CIRCUIT
(4) Install the lamp sockets. CONNECTOR RETAINING
(5) Pivot connector up and install retaining plate. PLATE
(6) Install gauge bezel and cluster lens.
Fig. 17 Cluster Connector Retaining Plate
GAUGE CLUSTER REPLACEMENT
(1) Remove 6 bezel screws (Fig. 18).
(2) Remove 6 gauge housing mounting screws (Fig.
19).
(3) Unplug the connector from cluster.
(4) To install, reverse the removal procedure.
GAUGE PACKAGE GAUGE REPLACEMENT

This procedure is to be performed with the
gauge cluster removed.
(1) Remove 2 screws from lens.
(2) Remove lens by tilting off of lower hooks (Fig.
20).
(3) Remove bezel.
(4) Remove screws holding appropriate gauge. J928F-6
(5) To install, insert gauge into housing.
Fig. 18 Gauge Cluster Bezel Removal/Installation
ILLUMINATION
COOLANT
TEMP
VOLTMETER FUEL GAUGE 4 W H E E L DRIVE
OIL P R E S S U R E GAUGE
SCREWS SCREWS INDICATOR
G A U G E SCREWS SCREWS J928E-28
Fig. 16 Gauge Package Printed Circuit Removal/Installation

G A U G E CLUSTER
G A U G E CLUSTER BEZEL
J928E-27
Fig. 19 Gauge Cluster Exploded View

(6) Install screws as required.
(7) Install bezel.
(8) Install lens.
8E - 26 YJ INSTRUMENT PANEL AND GAUGES
Fig. 20 Gauge Package Lens Removal

SPECIFICATIONS
INSTRUMENT PANEL GAUGES
O I L P R E S S U R E GAUGE C A L I B R A T I O N F U E L GAUGE C A L I B R A T I O N
POINTER POSITION RESISTANCE POINTER POSITION RESISTANCE
0 psi Grad. ± 3 ° 1 ohm Empty Grad. + 0 ° - 5 ° 1 ohm
40 psi Grad. ± 3.6° 47 ohms 1/2 Full Grad. ± 3.6° 44 ohms
80 psi Grad. ± 3.6° 89 ohms Full Grad. - 0 ° + 6 ° 88 ohms
T E M P E R A T U R E GAUGE C A L I B R A T I O N VOLTMETER CALIBRATION

POINTER POSITION RESISTANCE POINTER POSITION VOLTAGE I N P U T
100°F Grad. ± 3.5° 1365 ohms 12V Grad. ± 6 ° 12V ± 0.02V
210°F Grad. ± 2.5° 115 ohms 16V Grad. ± 3 ° 16V ± 0.02V
240°F Grad. ± 2.5° 55.1 ohms

J928E-5
INSTRUMENT CLUSTER GAUGES
SPEEDOMETER CALIBRATION TACHOMETER CALIBRATION

ENGINE FREQUENCY INDICATION ENGINE FREQUENCY INDICATION
33.3 HZ 1000 RPM ± 1 5 0
44.4 HZ 20 mph + 0 4 &6
-1.5 CYLINDER 100 HZ 3000 RPM ±250
+ 3 3 200 HZ 6000 RPM ± 2 5 0
122.2 HZ 55 mph
-0.3
4&6
+ 3 3
CYLINDER 166.7 HZ 75 mph
-0.3
+ 6
55.2 HZ 40 km/h
-0
+ 8
110.4 HZ 80 km/h
-0
+ 1
165.6 HZ 120 km/h °
-0 J928E-8
J AUDIO SYSTEMS 8F - 1
AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION 1 XJ SERVICE PROCEDURES 4
RADIO ANTENNA 7 YJ SERVICE PROCEDURES 6
GENERAL INFORMATION
DESCRIPTION play input of the radio through the relay contacts.
Each radio receives IGN feed from an ignition The radio panel illumination is dimmed for night
switch controlled fuse. There is an additional in-line driving.
fuse in the back of the radio chassis. The in-line fuse The electronically tuned radio requires an addi
will blow in the event an internal short occurs. tional connection to the (#11-YJ), (Dome #9-XJ) fuse
The ETR cassette radios protect the vehicle to retain the radio's memory when the ignition
from a radio failure with an in-line fuse located switch is turned OFF.
in the rear of the radio chassis (Fig. 1). The electronically tuned (ETR) radio is self
compensating. A radio trimmer adjustment is
not required.
DIAeiOSIS
•RADIO INOPERATIVE
Turn ignition switch to run.
• Inspect the (#7-YJ), (Radio #2-XJ) fuse and re
place if necessary.
• Measure voltage at battery side of the previously
CONNECTOR J898F-2 referenced fuse. There should be 12 volts at battery
side of fuse. If not, repair open from ignition switch.
Fig. 1In-Line Fuse Location
• Inspect in-line fuse at rear of radio and replace if
XJ/YJ vehicles are equipped with an Ignition-Off necessary.
Draw (IOD) fuse that is removed when the vehicles Turn ignition switch off.
are shipped from the factory. This fuse is in the • Disconnect radio connector. Measure resistance
Power Distribution Center to prevent battery dis from radio ground pin to a clean chassis ground.
charge during storage. For specific location refer to There should be zero ohms. If not, repair open be
Group 8W - Wiring Diagrams. tween radio connector and ground.
The (IOD) fuse is in the radio memory circuitry
and should be checked if the memory (time or radio NO AUDIO OUTPUT ON ONE OR MORE
station programming) is inoperative. SPEAKERS
All radios are connected to the radio illumination Refer to Radio Connector Pins.
relay. When the ignition switch is in RUN or ACCY
and the radio illumination relay remains de-ener FR01T SPEAKERS
gized, the radio receives battery voltage via the relay • Radio Off, radio connector disconnected. Measure
from the: resistance between radio left front feed and return
# (20 amp #7 fuse YJ) connector pins. Measure between right front feed and
• (10 amp ACCY fuse, XJ). return connector pins. The meter should read 5 to 8
The radio illumination relay is energized when the ohms. If the meter reading is correct, remove radio
headlamp switch is placed in the park or headlight for service. If not, repair wiring or replace speakers
position. Battery voltage is switched to the dim dis as required.
8F - 2 AUDIO SYSTEMS J
REAR SPEAKERS RADIO NOISE DIAGNOSIS

• Radio Off, radio connector disconnected. Measure
resistance between radio left rear feed and return Noise, Static
connector pins. Measure between right rear feed and Hash, Etc.
return connector pins. The meter should read 5 to 8
ohms. If meter reading is correct remove radio for Check For Noise in the
Following Positions!
service. If not, repair wiring or replace speakers as
1 . Accessory (All Electrical
required. Accessories Off)
2. Engine Running
DISTORTED AUDIO OUTPUT ON ONE OR
MORE SPEAKERS
• With the radio on, substitute known good speaker Is
or speakers. If the sound is still distorted, remove ra "Static/NoisiS
Present
dio for service. r
W i t h Ign. Key in A c e ] N o
Yes X All Accessories/
WEAK OR NO RECEPTION; NO AUDIO Off
OUTPUT; BACKGROUND NOISE PRESENT Is
Ignition switch in run, radio on. Static/Noise
No Yes
• Inspect antenna cable and connector at radio and Present
W i t h Engine
tighten or repair as necessary.
Running?.
• Unplug coax cable and connectors from radio. Mea Refer to
sure resistance from center conductor to coaxial Antenna
Diagnosis
shield. The meter should read infinite resistance
Check Following:
(open). If it does not, replace antenna assembly. f A . Electric Fuel Pump
• Measure resistance of antenna mast to tip of cen B. Ignition System Faults
ter conductor at radio end of cable. The meter should Stop C. Faulty Ground Connections
read 0 to 0.5 ohms. If it does not, replace lead-in ca D. Faulty Electronic Voltage Reg.
J928F-3 E. Tighten Antenna Mounting N u t
ble or antenna assembly.
• Measure resistance from coaxial shield to chassis
RADIO DISPLAY ILLUMINATION DIMMING CIRCUIT
ground (vehicle body). The meter should read zero
Turn headlamp switch to PARK for voltage
ohms. If it does not, ground antenna base to vehicle
tests; turn headlamp switch to OFF for resis
body, or replace antenna assembly as required
tance tests.
For all problems with no or low audio output
• Separate relay connector from relay. Measure re
not resolved by these tests, remove radio for ser
sistance from relay connector pin 2 to a clean chassis
vice.
ground. The meter should read zero ohms. If not, re
MEMORY DOES NOT OPERATE pair open between relay connector and ground.
• Inspect (F16-YJ), (Fl-XJ) fuse located in the • Measure voltage at radio illumination Relay pin 5.
Power Distribution Center and replace if necessary. There should be battery voltage. If not repair open
• Measure voltage at battery side of previously ref from headlamp switch.
erenced fuse. There should be 12 volts at battery side • Measure voltage at radio illumination relay pin 4.
of fuse. If not, check the Maxi fuse. Voltage should vary with dimmer switch. If OK, go
Refer to Group 8W - Wiring Diagrams. to next step. If not, repair open circuit between pin 4
• Measure voltage at radio connector pin 4. There and interior lamp rheostat.
should be 12 volts. If meter reading is correct, re • Measure voltage at radio illumination relay pin
move radio for service. If not, repair open from fuse 10. Voltage should vary with dimmer switch. If OK,
panel. remove radio for repair by authorized outlet. If not,
replace radio illumination relay.
RADIO DISPLAY ILLUMINATION (PARK AND
HEADLIGHTS OPERATING NORMALLY) NOISE INTERFERENCE CHANGES WITH
Headlamp switch off, radio on. ENGINE SPEED
• Measure voltage at radio connector pin 10. There • Inspect connections at:—Generator —Ignition
should be 12 volts. If not, go to next step. If OK, re module —Antenna coaxial ground —Radio ground
move radio for repair by authorized outlet. —Body to Engine Block (braided ground strap). Re
• Measure voltage at illumination relay pin 3. There pair as required.
should be 12 volts. If 12 volts is present, replace il
lumination relay. If not, repair open in circuit.
• Inspect ignition secondary:—Wire routing —Condi RADIO CONNECTOR PINS

tion of wire insulation —Distributor. Reroute or re
place as required.
RADIO ILLUMINATION RELAY

4 5
MJ
The radio illumination relay is in the relay center.
The relay center is located on the lower instrument
panel trim cover just right of the steering column P Q P _ O O P
(Fig. 2). e
12 10
13 11
1 - RIGHT R E A R F E E D 8 — LEFT REAR R E T U R N

2 - RIGHT F R O N T FEED 9 - LEFT F R O N T R E T U R N
3 - ACC./IGN 10 - DISPLAY DIMMING
4- BATTERY 11 - PANEL DIMMING
5 - BLANK 12 - RIGHT F R O N T R E T U R N
6 - LEFT R E A R FEED 13 - RIGHT R E A R R E T U R N
7-L E F T F R O N T FEED
N O T E : FOR W I R E COLORS REFER T O

GROUP 8 W — W I R I N G DIAGRAMS
J938F-11
RELAY
CENTER
LOWER
INSTRUMENT
PANEL J938F-12
Fig. 2 Radio Illumination Relay
YJ
The radio illumination relay is tapped in the har
ness above the radio.
8F - 4 AUDIO SYSTEMS
XJ SERVICE PROCEDURES
RADIO REPLACEMENT ANTENNA
(1) Disconnect negative cable from battery. LEAD
(2) Remove instrument panel bezel attaching
screws (Fig. 1) and remove the bezel.
BEZEL SNAP FIT
ATTACHING LOCATION
SCREWS
GROUND ELECTRICAL
LEAD CONNECTOR J898F-2
Fig. 3 Disconnect/Connect Radio Wiring Harnesses
SNAP FIT
LOCATIONS J928E-21
Fig. 1 instrument Bezel Removal/Installation

(3) Remove radio attaching screws (Fig. 2).
J898F-3
Fig. 4 Install Clip In Underside of Dash

RADIO SPEAKERS
FRONT DOOR-MOUNTED RADIO SPEAKERS
(1) Remove interior door latch release assembly
and control panel retaining screws (Fig. 5).
CONTROL
PANEL RETAINING
SCREWS
J898F-1
Fig. 2 Remove/Install Radio Mounting Screws

(4) Disconnect radio electrical connector, ground
lead and antenna lead (Fig. 3).
(5) To install radio, route harness above and to the J906S-1
right of the radio cavity. Install the radio making
sure that clip on top of radio (Fig. 4) is installed on Fig. 5 Power Window Control Panel Removal/
mating slot in dash. Installation
(6) Reverse removal procedures to finish installing (2) Disconnect control linkage and wire harness
the radio. connector.
(3) Remove latch release and control panel assem (9) To install a speaker, connect the speaker wire
bly. harness and reverse the removal procedure.
(4) Remove armrest lower retaining screws.
REAR LIFTGATE-MOUNTED RADIO SPEAKER
(5) Swing armrest downward to a vertical position.
This is necessary to disconnect armrest from upper REMOVAL
retainer clip (Fig. 6).
(1) Remove 2 screws at top outside edges of liftgate
trim panel.
(2) Remove trim panel with a wide flat blade tool
(Fig. 8).
To aid in removal of trim panel, start at the
bottom of the panel.
J898F-5
Fig. 8 Liftgate Trim Panel Removal

(3) Remove speaker attaching screws (Fig. 9).
(4) Disconnect speaker at wiring harness and re
move speaker.
JW8S-7
Fig. 6 Armrest Retainer Clip
(6) Pull armrest straight out from trim panel.
(7) Remove trim panel with a wide flat blade tool
(Fig. 7).
To aid in removal of trim panel, start at the
bottom of the panel.
J898F-4
Fig. 9 Liftgate Speaker

INSTALLATION
(1) Connect speaker at wiring harness.
(2) Install speaker.
Fig. 7 Trim Panel Removal (3) Install trim panel by pushing in the plastic
(8) Remove speaker attaching screws and discon trees.
nect speaker at wire harness. (4) Install door panel screws.
Y J SERVICE PROCEDURES
RADIO REPLACEMENT PARKING MOUNTING
BRAKE STUDS
(1) Disconnect negative cable from battery. ASSEMBLY
(2) Remove gauge cluster panel bezel attaching
screws (Fig. 1).
FRONT
CABLE
•J8905-88
Fig. 2 Parking Brake Assembly

J928F-6
(3) Reach up behind instrument panel and remove
Fig. 1 Gauge Cluster Bezel Removal/Installation 4 stamped nuts holding speaker in place.
(4) Disconnect speaker electrical connector and re
(3) Remove radio bezel.
move speaker.
(4) Remove radio attaching screws.
(5) Disconnect radio antenna cable. SOUND BAR-SPEAKER REMOVAL
(6) Disconnect radio wire harness. (1) Pull sound bar padding away from bar on the
(7) Remove radio. passenger side (Fig. 3).
(8) To install radio, reverse the removal proce
dures.
RADIO SPEAKERS
PASSENGER 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.
DRIVERS SIDE
The speaker is located behind grille panel at left
end of the dash panel.
(1) Remove nuts that attach the parking brake
pedal assembly mounting studs to the dash panel.
The nuts are accessible from the engine compartment
(Fig. 2).
J918F-1
CAUTION: If vehicle is equipped with a rear window
wiper, there is a ground wire attached to top of bolt
Fig. 3 Sound Bar Speaker Connector
that attaches the pedal assembly to the instrument
panel. (2) Disconnect speaker harness connector located
on the passenger side at the sound bar.
(2) Remove bolt that attaches the pedal assembly (3) Remove screws holding speaker grille and
to the instrument panel and allow pedal assembly to speaker to bar.
fall out of the way.
(4) Disconnect wires from speaker and remove

speaker.
(5) To install speaker, reverse the removal proce
dures.
SOUND BAR REPLACEMENT

(1) Disconnect speaker harness connector located
on the passenger side at the sound bar (Fig. 3)
(2) Remove bolts attaching the sound bar side
flanges to the right and left side bars.
(3) Open zipper on sport bar cover.
(4) Remove bolts attaching the sound bar brackets
to the sport bar (located on the rear of the sport bar)
(Fig. 4). Slip brackets through the sport bar cover.
(5) To install the sound bar, reverse the removal Fig. 4 Rear Sound Bar Attaching Bolt
procedures.
RADIO ANTENNA
INDEX
page page
Antenna Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacement 7
General Information . 7
GENERAL INFORMATION
AM/FM radio model antennas must have a good
ground to eliminate static. The antenna mast is con
nected to the inner wire of the co-axial cable and is
not grounded to any part of the vehicle. The coaxial
shield (the wire mesh) surrounding the center con
ductor wire of the antenna lead-in cable is grounded
to the radio and the antenna base.
REPLACEMENT
XJ
(1) Remove the fender inner splash panel mount
ing nuts (Fig. 1) and move the panel aside to gain ac
cess to the antenna base and cable.
The splash panel serews may be covered with
undercoating.
(2) Remove the antenna mast, nut and antenna
pad from the top of the fender (Fig. 2).
(3) Remove the passenger side kick panel.
(4) Disconnect the antenna lead (Fig. 3) by pulling
apart while twisting the metal connectors. DO NOT
Fig. 1 Remove/Install Fender Inner Splash Panel
PULL ON THE COAX CABLE.
(5) Pull the rubber grommet out of the kick panel. YJ
(6) Remove the antenna assembly from inside the (1) Remove the radio as described in Radio Re
wheel well. placement.
(7) To install the antenna, reverse the removal (2) Remove three screws holding the antenna base
procedure. and pad to the body (Fig. 4).
(8) Verify antenna and radio operation. (3) Pull the antenna and cable out of the vehicle.
(9) Apply 3M Rubberized Undercoating, or equiva
lent to the splash panel screws.
(6) Install the antenna into the radio and install

the radio.
J898F-13 ANTENNA TESTS

Antenna ground continuity is checked with an
Fig. 2 Remove/Install Nut and Antenna Pad
ohmmeter. The following four tests are required (Fig.
5):
• Mast-to-ground test 1.
• Tip of mast-to-tip of conductor test 2.
• Body ground-to-battery ground test 3.
• Body ground-to-coaxial shield test 4.
Ohmmeter test lead connections are shown in the
following schematic.
MAST-TO-GROUND TEST f .
Test 1 determines if the antenna mast is insulated
from the base. Procedure is as follows:
• Connect one ohmmeter lead to the tip of the an
tenna mast and the other lead to the antenna base.
• With the antenna disconnected from the radio,
there should not be continuity.
TIP OF MAST-TO-TIP OF CONDUCTOR TEST 2 .

Test 2 checks the antenna for an open circuit as
follows:
J898F-14 • Disconnect the antenna cable from the radio.
• Connect one ohmmeter test lead to the tip of the
Fig. 3 Disconnect Antenna Lead
mast and the other lead to the tip of the antenna ca
(4) To install the antenna, make sure the antenna ble lead-in (the part inserted into the radio).
pad is placed over the cable and guide the cable un • Continuity should exist (ohmmeter should only
der the instrument panel. register a fraction of an ohm). High or infinite resis
(5) Secure the antenna base and pad with three tance suggests damage to the base and cable assem
screws. bly that should be replaced.
AUDIO SYSTEMS 8F - 9
BODY GROUND'TO-BATTERY GROUND TEST

•o o- 3.
2 Test 3 checks condition of the vehicle body ground
connection as follows:
• Connect one ohmmeter test lead to the vehicle
1 fender and the other lead to the battery negative
post.
• Resistance should be less than one ohm.
• If resistance is more than one ohm, check the
braided ground strap connected to the engine and ve
hicle body for being loose, corroded, or damaged. Re
pair as necessary.
BODY GROUND*TO°>COAMIAL SHIELD TEST 4 .

Test 4 checks condition of the ground between the
antenna base and vehicle body as follows:
• Connect one ohmmeter test lead to the fender and
the other lead to the crimp on the coaxial shield.
• Resistance should be less then one ohm.
J898F-7 • If resistance is more then one ohm, replace the an
tenna base attaching screws with new cadmium
Fig. 5 Antenna Tests plated screws.
J HORNS 8G - 1
HORNS
CONTENTS
page page
GENERAL INFORMATION 1 XJ 1
HORN SWITCH (HORN PAD) REPLACEMENT .3 YJ 3
TORQUE SPECIFICATIONS 4
GENERAL INF
For XJ/YJ vehicles battery voltage is applied to the wheel allows the switch circuit to maintain contact
horn relay through a fuse. while allowing rotation of the steering wheel.
,When the horn switch is depressed, the horn relay A cadmium-plated ground screw is used to at
is grounded, pulling the contact closed and providing tach the horn(s) to the b o d y . Do not substitute
battery voltage to the horns. other types of ground screws as they may be
A slip ring and brush arrangement in the steering come corroded and cause a loss of ground (XJ).
XJ
REPLACEMENT
(1) Raise and support the vehicle.
(2) Remove the splash shield.
(3) Remove horn mounting bolt and horn mounted
on the drivers side (Fig. 1).
(4) To install, reverse the removal procedures.
DIAGNOSIS AND REPAIR

Refer to Group 8W - Wiring Diagrams for a com
plete circuit diagram.
HORNRELAY
• Inspect HDLP/DLY fuse. Replace fuse as required.
• Depress Horn Switch. The relay contacts should
click. If ok, go to HORNS. If not, go to next step.
• Remove the horn relay located in the relay center.
The relay center is on the lower instrument panel
trim cover just right of the steering column (Fig. 2).
There should be 12 volts at relay connector pin 1. If
not, repair open in circuit to relay.
• Depress horn switch. Measure resistance between
relay connector pin 5 and ground. The meter should
read zero ohms. If not, repair open to horn switch
ground.
• Measure resistance between relay connector pin 4
and ground. The meter should read almost zero ohms
(horn resistance) If OK, replace relay. If not, repair J918G-1
open in circuit between relay and horns.
Fig. 1 Drivers Side Horn
8G - 2 HORNS J
HORNS
• Disconnect horn connector. Depress Horn Switch.
There should be 12 volts at the horn connector. If
OK, replace horns. If not, repair open to relay.
• Measure the resistance between the horn bracket
and chassis ground. The meter should read zero
ohms. If not, check mounting screw for corrosion and
replace as necessary.
LOWER INSTRUMENT
Fig. 2 Horn Relay

HORNS 8G - 3
YJ
Wrangler/YJ horns are located on the drivers side
inner fender.
REPLACEMENT
(1) Disconnect wire harness connector from the
horn (Fig. 3).
(2) Remove horn and bracket mounting bolt. Horn
and bracket are removed as an assembly.
DIAGNOSIS AND REPAIR

Refer to Group 8W - Wiring Diagrams for a com
plete circuit diagram.
HORN RELAY
• Inspect 10 amp fuse, #F15, located in the Power
Distribution Center. Replace fuse as required.
• Depress Horn Switch. The relay contacts should
click. If ok, go to HORNS. If not, go to next step.
MOUNTING
• Remove relay from Power Distribution Center. BOLT
There should be 12 volts at cavities 2 and 5. If not,
repair open in circuit to relay. Fig. 3 Horn Removal/Installation—YJ
• Depress horn switch. Measure resistance between HORN
relay cavity 1 and ground. The meter should read • Disconnect horn connector. Depress Horn Switch.
zero ohms. If not, repair open to horn switch ground. There should be 12 volts at the horn connector pin A.
• Measure resistance between relay cavity 4 and If OK, replace horn. If not, repair open to relay.
ground. The meter should read almost zero ohms • Measure the resistance between the horn connec
(horn resistance) If OK, replace relay. If not, repair tor pin B and chassis ground. The meter should read
open in circuit between relay and horn. zero ohms. If not, repair open to ground.
HORN SWITCH (HORN PAD) R E P L A C E M E N T
(1) Disconnect negative cable from battery. CONTACT

EXTENSION
(2) Remove horn button by pulling straight up. WASHER PIN
(3) Remove horn button components (Fig. 4).
(4) To install the switch, reverse the removal pro
cedures.
(5) Connect negative cable to battery. RETAINING
NUT
CANCELING
CAM
INSULATOR
HORN
BUSHING J8919-110
BUTTON
Fig. 4 Steering Wheel Removal/Installation

8G - 4 HORNS
COMPONENT TORQUE
Horn Bracket
20 N m (15 ft. lbs.)
Screw
J918G-4
J VEHICLE SPEED CONTROL SYSTEM 8H - 1
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
SERVICE PROCEDURES 8 TEST PROCEDURES 5
GENERAL INFORMATION TO ACTIVATE: Put ON/OFF switch in ON posi

The vehicle speed control system (Fig. 1) is electri tion. When the desired speed is achieved, push and
cally actuated and vacuum operated. The turn signal release the SET button to turn on and engage the
lever on the steering column incorporates a slide system. Remove foot from accelerator. Speed will be
switch that has three positions OFF, ON or RE maintained at this level.
SUME. A SET button is in the end of the lever. This TO DEACTIVATE; A soft tap of the brake pedal,
device is designed to operate at speeds above approx normal brake application or depressing the clutch
imately 35 mph. pedal while the system is engaged will disengage
speed control without erasing memory. A sudden in
WARNING; T H E U S E O F S P E E D C O N T R O L I S NOT crease in engine R.P.M. may be experienced if the
R E C O M M E N D E D W H E N DRIVING CONDITIONS DO clutch pedal is depressed while the speed control sys
NOT P E R M I T MAINTAINING A C O N S T A N T S P E E D , tem is engaged. Moving the slide switch to the OFF
S U C H A S HEAVY T R A F F I C O R ON R O A D S T H A T position or turning the ignition OFF also disengages
A R E WINDING, ICY, S N O W C O V E R E D , O R S L I P the system and in addition erases the memory.
PERY.
SERVO, VACUUM S U P P L Y
BRACKET A N D HOSE
CABLE A S S E M B L Y
4.0L
FWD ^VACUUM R E S E R V O I R J928H-1
Fig. 1 Speed Control System

8H - 2 VEHICLE SPEED CONTROL SYSTEM
TO RESUME AFTER BREAKING: After disen TO ACCELERATE FOR PASSING: Depress ac
gaging the speed control system by tapping the brake celerator as needed. When passing is completed, re
pedal or clutch pedal, push the RESUME/ACCEL lease accelerator and vehicle will return to previous
button to return vehicle to the previously set speed. speed setting. There may be a slight (3-7 mph) speed
SET/COAST: Speed can be decreased by holding loss before the vehicle recovers to the set speed.
SET button against stop until desired speed is at TO ACCELERATE: While speed control is en
tained. Releasing the button engages the system at
gaged, hold the RESUME/ACCEL button depressed
that speed. A decrease in speed also can be attained
by tapping brake pedal lightly disengaging system. and release at a new desired speed. This will allow
When desired speed has been obtained push and re the vehicle to accelerate and set at a higher speed
lease SET button. setting.
VEHICLE SPEED CONTROL SYSTEM 8H 3
WARNING: T H E USE OF THE SPEED CONTROL S T A R T ENGINE.

IS NOT RECOMMENDED WHEN DRIVING
CONDITIONS DO NOT PERMIT
MAINTAINING A CONSTANT SPEED, SUCH
AS HEAVY TRAFFIC OR ON ROADS THAT r *
ARE WINDING, ICY, SNOW COVERED OR SLIPPERY.
ACCELERATE VEHICLE SPEED CONTROL
T O DESIRED S P E E D ENGAGES WHEN
ENGINE IS STARTED
MOVE SLIDE SWITCH FAULTY

TO "ON" POSITION. ELECTRICAL CIRCUIT*
DEFECTIVE
SERVO
SPEED CONTROL ENGAGES
PUSH AND
WITHOUT PRESSING T H E
" S E T BUTTON RELEASE " S E T " BUTTON
F A U L T Y ELECTRICAL CIRCUIT*
O R CONTROL SWITCH R E M O V E F O O T FROM
ACCELERATOR. S P E E D
SHOULD BE CONTROLLED
DEFECTIVE SERVO
HUNTING SURGE EXCESSIVE SAG

NO SPEED CONTROL SPEED SETTING AFTER
OR SPEED ON HILLS OR
WHEN SET BUTTON IS LOCK-IN, TOO HIGH OR
VARIATIONS AT IN TRAILER
PRESSED AND RELEASED TOO LOW
LOW SPEEDS TOWING
+ 1
LOCK-UP ENGINE
FUSE BLOWN TORQUE CONVERTER VACUUM LEAK
PERFORMANCE
ROUGHNESS
AMPLIFICATION
NO VACUUM VACUUM
OF ENGINE DEFECTIVE SERVO
AT SERVO LEAK
SURGE
EXCESSIVE LOAD
SPEED CONTROL
MAY REQUIRE DBICTIVE
THROTTLE CABLE DEFECTIVE SERVO
DISCONNECTED
MANUAL ASSISTANCE CABLE
O N HILLS
IMPROPER S T O P LAMP DEFECTIVE VACUUM DEFECTIVE VACUUM

DEFECTIVE
AND SPEED CONTROL RESERVOIR RESERVOIR
CAKE (CHECK VALVE)
SWITCH ADJUSTMENT
FAULTY ELECTRICAL DBfCTIVE

CIRCUIT* ENGINE CONTROLLER
DEFECTIVE S E R V O
•TESTS AND ADJUSTMENTS ARE DESCRIBED

DEFECTIVE
IN APPROPRIATE SECTION OF SERVICE
VACUUM RESERVOIR
MANUAL
J918H-15
4 VEHICLE SPEED CONTROL SYSTEM 4
I
DRIVE VEHICLE O V E R
R O U G H ROAD
UNIT DISENGAGES ON T A P B R A K E PEDAL LIGHTLY,

ROUGH ROAD SPEED CONTROL SHOULD
DISENGAGE
NO SYSTEM
I M P R O P E R A(X I U S T M E N T
SPEED CONTROL DISENGAGEMENT WHEN
O F S T O P UW P A N D
DISENGAGES BRAKE P E D A L IS
S P E E D C O N T RO L S W I T C H *
DEPRESSED
DEFECTIVE O R IMPROPERLY
FAULTY
A D J U S T E D S T O P LAMP
ELECTRICAL
AND SPEED
CIRCUIT
CONTROL SWITCH
SPEED CONTROL
T H R O T T L E CABLE
K I N K E D O R DAMAGED
MOVE SLIDE SWITCH TO THE

THE "RESUME" POSITION
VEHICLE SHOULD RESUME PRE
FAULTY ELECTRICAL
ENGINE DOES VIOUSLY MEMORIZED SPEED
CIRCUIT*
NOT RETURN TO
NORMAL IDLE
SPEED CONTROL THROTTLE DEFECTIVE SERVO

CABLE K I N K E D O R VEHICLE RESUMES
DAMAGED SPEED
STANDARD THROTTLE DEPRESS BRAKE RESUME SPEED

LINKAGE F A U L T S PEDAL, S P E E D CONTROL IS POSSIBLE
SHOULD DISENGAGE BELOW 20 M.P.H.
DEFECTIVE DISTANCE
N O SYSTEM DISENGAGE SENSOR
NO RESUME WHEN SPEED CONTROL
W H E N BRAKE PEDAL IS
SLIDE SWITCH IS MOVED DISENGAGES
DEPRESSED
1
DEFECTIVE
DEFECTIVE E N G I N E ENGINE CONTROLLER
DEFECTIVE SWITCH
CONTR< DLLER
FAULTY ELECTRICAL S P E E D CONTROL FAULTY ELECTRICAL

CIRCUIT* SYSTEM OK CIRCUIT*
STICKY BRAKE SWITCH
J918H-14
J VEHICLE SPEED CONTROL SYSTEM 8H - §
TEST PROCEDURES
INDEX
page page
Checking for Diagnostic Trouble Code ......... 5 Speed Control Switch (Turn Signal Lever) Test . . . 7
Electrical T e s t s at Powertrain Control Module .... 6 Stop Lamp Speed Control Switch Test 7
Electrical T e s t s at Servo . . . . . . . . . . . . . . . . . . . . 5 Vacuum Supply Test 7
Inoperative System 5 Vehicle Speed Control System Electrical T e s t s ... 5
Operational Check (Road Test) 8 Vehicle Speed Sensor Test . . . . . . . . . . . . . . . . . . 5
Road Test 5
ROAD TEST VEHICLE S P E E D S E N S O R T E S T

Refer to Operational Check (ROAD TEST) section For testing of the Vehicle Speed Sensor and related
to verify reports of speed control system malfunction. components, refer to Powertrain Diagnostic Proce
dures manual.
INOPERATIVE S Y S T E M
Road test vehicle to verify reports of speed control VEHICLE S P E E D CONTROL S Y S T E M ELECTRICAL
system malfunction. An inspection should be made TESTS
for loose electrical and vacuum connections at the Vehicle speed control systems may be tested using
servo. two different methods. One involves use of a DRB II
Check for correct installation of the vacuum check Scan Tool. If this test method is desired, refer to
valve in the hose from servo to vacuum source. The Powertrain Diagnostic Procedures manual.
word VAC on the valve must point toward the vac The other test method uses a voltmeter. The volt
uum source. meter method is described in the following tests.
Corrosion should be removed from electrical termi If any information is needed concerning wiring, re
nals and a light coating of Mopar Multipurpose fer to Section 8W - Wiring Diagrams.
Grease, or equivalent, applied.
Inspection also should be made to verify that both CAUTION: When test probing for voltage or conti
ends of the speed control cable are securely attached. nuity at electrical connectors, care must be taken
not to damage connector, terminals, or seals. If
CHECKING F O R DIAGNOSTIC T R O U B L E CODE these components are damaged, intermittent or
(1) When trying to verify a speed control system complete system failure may occur.
electronic malfunction use a DRB II Scan Tool to find
the cause (refer to Powertrain Diagnostic Procedures
manual). ELECTRICAL TESTS AT SERVO
If DRB II is not available, the Diagnostic Trouble (1) Turn ignition switch to the ON position. With
Code may be determined with the following method: speed control switch in the ON position, setup a volt
(a) With key inserted in ignition switch, cycle meter to read battery voltage and connect negative
switch to ON position 3 times. On third cycle, leave lead to a good chassis ground.
switch in ON position. (2) Disconnect 4-way connector going to servo (Fig.
(b) After switch has been cycled 3 times, observe 2). Blue wire with red tracer of main harness 4-way
Malfunction Indicator Lamp CHECK ENGINE on connector should read approximately battery voltage.
instrument cluster. If a DTC is present, the code If not, check for loose connections, brake switch ad
will be displayed in a series of flashes representing justment or, repair main harness as necessary.
digits. Three flashes in rapid succession, a slight (3) Connect a jumper wire between male and fe
pause, then 4 flashes in rapid succession would in male terminals of blue wire with red tracer. The
dicate DTC 34). other 3 male terminals from servo should show bat
(2) If a DTC 34 is observed, perform tests in the tery voltage. If not, replace servo.
sections Electrical Tests at Servo and Electrical Tests (4) Using an ohmmeter, connect one lead to a good
at Powertrain Control Module. body ground. Touch other lead to black (BK) wire
If a DTC 15 is observed, perform test for a faulty terminal in 4-way connector of main harness. Meter
Vehicle Speed Sensor. should show continuity. If not, repair ground circuit
(3) Correct any problems found when performing as necessary.
these tests and recheck for DTC if changes were
made.
8H - 6 VEHICLE S P E E D CONTROL S Y S T E M J
Fig. 4 Powertrain Control Module 60-Way Connector

Shown from Terminal End
(4) Touch positive lead of the voltmeter to terminal
in cavity number 53. As in step (3), voltmeter should
read 0 volts with switch in OFF position and battery
voltage with switch in ON position.
(5) Touch positive lead of voltmeter to terminal in
cavity number 48. With speed control switch in OFF
position, voltmeter should read 0 volts. With switch
in ON position, voltmeter should read battery volt
age. Pressing SET button should cause voltmeter to
change from battery voltage to 0 volts for as long as
the switch is held. If not, perform the speed control
Fig. 2 Servo And Harness Connector switch test. If the switch is not at fault, then check
ELECTRICAL T E S T S A T P O W E R T R A I N CONTROL main harness and repair as necessary.
MODULE (6) Touch positive lead of voltmeter to terminal in
(1) Unplug 60-way connector from Powertrain Con cavity number 50. The voltmeter should read 0 volts
trol Module, located on drivers side fender (Fig. 3). with speed control switch in either OFF or ON posi
tion. With switch in either RESUME or SET posi
tion, voltmeter should read battery voltage. If not,
perform the speed control switch test. If the switch is
not at fault, then check main harness and repair as
necessary.
(7) Touch positive lead of voltmeter to terminal in
cavity number 49. The voltmeter should read 0 volts
with switch in OFF position. With switch in ON po
sition, voltmeter should read battery voltage. The
voltmeter will continue to read battery voltage when
either the SET or RESUME switch is pressed. If not,
perform the speed control switch test. If switch is not
at fault, then check main harness and repair as nec
essary.
(8) Using an ohmmeter, connect one lead to a good
body ground and touch other lead to terminal in cav
ity number 29. With brake pedal released, meter
Fig. 3 Powertrain Control Module and Connector should show continuity. When pedal is depressed,
Location meter should show open circuit.
(2) Connect negative lead of voltmeter to a good
body ground near module.
(3) For the following tests, ignition switch must be
in ON position. Refer to Fig. 4 for controller terminal
locations. Touch positive lead of voltmeter to termi
nal in cavity number 33. With speed control switch
in OFF position, voltmeter should read 0 volts. With
speed control switch in ON position, voltmeter should
read battery voltage. If not, repair main harness as
necessary.
J VEHICLE SPEED CONTROL SYSTEM 8H - 7
SPEED CONTROL SWITCH (TURN SIGNAL LEVER)

TEST
J898H-17
STOP LAMP SPEED CONTROL SWITCH TEST

(1) Disconnect double connector at switch pigtail
and connect a 12 volt source to either terminal. Con
nect a test lamp between other terminal and a good
ground. The test lamp should be on when brake
pedal is in normal position. The test light should go
off when brake pedal is depressed approximately 3/8
of an inch. Fig. 5 Vacuum Gauge Test
(2) If test lamp does not respond properly, the stop
lamp switch is defective or out of adjustment. (2) Start engine and observe gauge at idle. Vac
(3) Stop lamp switch adjustment is detailed in uum gauge should read at least ten inches of mer
Group 5 - Brakes section of this manual. cury.
(3) If vacuum does not meet this requirement,
VACUUM S U P P L Y T E S T check for vacuum leaks or poor engine performance.
(1) Disconnect vacuum hose at servo or vacuum re
ceiver and install a vacuum gauge in hose (Fig. 5).
SET/COAST POSITION 1-2 1-4 2-4

2-3
(S/C) sw SLIDER
Normal Off O o O O O o
Normal On O o O O c o
Normal R/A c . O c O c o
Depressed Off o o o c o o
Depressed On o o o c c c
Depressed R/A c c c c c c
C — C L O S E D (ZERO OHMS)
0 — O P E N ( oo (INFINITE) )
GREEN WIRE, TOP, # 2

YELLOW WIRE, BOTTOM, # 1
/
BLUE WIRE, TOP, # 4 \

RED WIRE, B O T T O M , # 3
J898H-16
8H - 8 V E H I C L E S P E E D CONTROL SYSTEM
J
O P E R A T I O N A L CHECK (ROAD T E S T ) (5) Release speed switch back to ON. Vehicle will
The following sequential checks are performed with hold the new faster speed, if set speed button has
the speed switch ON and vehicle speed faster than 35 been pressed.
mph: (6) Tap brake pedal. Vehicle will decelerate.
(1) Press the set button in end of multi-function le If vehicle has a manual transmission, repeat step 6
ver. Vehicle should maintain set speed. by depressing the clutch.
(2) Hold set button in, and remove foot from accel (7) Slide speed switch momentarily R/A. Vehicle
erator. Vehicle should coast to a slower speed. will accelerator to former set speed.
(3) Release set button. Speed control will engage (8) While cruising, accelerate, then remove foot
and hold a slower speed, provided the speed remains from accelerator. Vehicle will coast back to set speed.
above 35 mph. (9) While speed is engaged, tap set speed button.
(4) Slide speed switch to R/A and hold it there. Ve Vehicle speed will increase 1 mph for each time set
hicle should accelerate. speed button is tapped.
SERVICE PROCEDURES
SPEED CONTROL SERVO REPLACEMENT (4) Insert servo studs through holes in servo
mounting bracket.
REMOVAL (5) Install 2 attaching nuts and tighten to 6 N»m
(1) Disconnect vacuum hose at servo (Fig. 1). (50 in. lbs.).
(2) Disconnect electrical connector at servo. (6) Connect vacuum hose to servo.
(3) Remove 2 nuts from servo mounting bracket. (7) Connect electrical connector to servo terminals.
(4) Pull servo away from mounting bracket.
(5) Remove and discard push nuts on servo studs. SERVO CABLE REPLACEMENT
(6) Pull speed control cable away from servo to ex
pose cable retaining clip. CAUTION: Use finger pressure only to remove the
(7) Remove clip attaching cable to servo. speed control cable connector at the bell crank. Pli
ers or screwdriver can brake connector requiring
complete cable replacement.
(1) Using finger pressure only, remove speed con

trol cable connector at bell crank by pushing connec
SPEED CONTROL
SERVO tor off the bell crank (Fig. 2). DO NOT try to pull
connector off perpendicular to the bell crank.
(2) Squeeze tabs on speed control cable and push
out of locking plate (Fig. 3).
(3) Pull cable out of cable guide.
(4) Remove 2 nuts and cable housing from servo.
(5) Release cable clip from servo cable and remove
servo cable.
(6) To install, reverse the removal procedure.
S P E E D CONTROL S W I T C H R E P L A C E M E N T
(2) Remove horn button with a push and turn mo
tion.
J928H-2 (4) Turn key to lock position and remove steering
wheel nut and washer.
Fig. 1 Speed Control Servo (5) Scribe an alignment mark on the steering in
line with the mark already existing on the end of the
INSTALLATION steering column.
(1) With throttle blocked to full open position, (6) Remove vibration damper from the steering col
align hole in cable sleeve with hole in servo pin and umn hub, if equipped.
install retaining clip. (7) Remove steering wheel using a steering wheel
(2) Insert servo studs through holes in cable puller.
sleeve.
(3) Install new push nuts on servo studs.
J VEHICLE SPEED CONTROL S Y S T E M 8H - 9
EXTENSION CONTACT
Fig. 4 Steering Wheel Removal/Installation

TEMPT TO REMOVE THE LOCKPLATE W I T H O U T
COMPRESSOR TOOL C4156 AS T H E L O C K P L A T E
IS UNDER HEAVY SPRING TENSION.
(8) Compress lockplate with compressor tool

Fig. 2 Remove Bell Crank Connector
C4156.
(9) Remove steering shaft snap ring (Fig. 5). Dis
card snap ring. It is not reusable.
Fig. 3 Remove/Install Speed Control Cable to J8919-120

Locking Plate
WARNING: TO REMOVE T H E STEERING SHAFT Fig. 5 Lockplate Removal
S N A P RING IN THE F O L L O W I N G STEP, THE LOCK- (10) Remove compressor tool.
P L A T E MUST BE COMPRESSED, DO NOT AT-
8H - 1 0 VEHICLE SPEED CONTROL SYSTEM
(11) Remove lockplate, cancelling cam, and upper

bearing preload spring.
(12) Remove horn button components from cancel
ing cam.
(13) Remove screw and hazard warning switch
knob.
(14) Remove actuator arm attaching screw.
(15) Remove turn signal switch attaching screws.
(16) Unplug speed control switch connector.
(17) Pull speed control harness out of the column.
(18) Insert ignition key in lock cylinder and turn
key to ON position.
(19) Remove key warning buzzer switch and re
taining clip with a paper clip inserted below retainer
so that retainer is flattened (Fig. 6).
Do not attempt to remove buzzer switch and
clip separately. The clip could fall into the col
umn jacket.
K E Y / L O C K CYLINDER
RETAINING S C R E W J8919-125
Fig. 7 Lock Cylinder Removal/Installation

ATTACHING SCREWS HOUSING A N D
Fig. 6 Buzzer Switch Removal

(20) Remove ignition lock cylinder retaining screw
and pull lock cylinder out of column housing (Fig. 7). J898K-24
(21) Remove screws that attach housing and
Fig. 8 Steering Column Housing
shroud assembly to column jacket and carefully re
Removal/Installation
move housing and shroud assembly (Fig. 8).
Do Not let dimmer switch rod, lock pin or lock (26) Push on dimmer switch rod to make sure it is
rack fall out. connected then carefully position housing and shroud
(22) Remove turn signal/wiper lever by pulling it assembly to column (Fig. 10).
straight out of column. Make sure nylon spring retainer on the lock
(23) Remove wiper switch cover from back of hous pin is positioned forward of retaining slot of
ing and shroud assembly (Fig. 9). If equipped with lock rack (Fig. 10).
column shift, remove screw holding the cover on. Position the first tooth of gear (farthest from
(24) Remove pivot screw from housing and remove the block tooth) with the most forward tooth of
wiper switch. lock rack.
(25) Install a new switch and switch cover.
J VEHICLE S P E E I CONTROL SYSTEM 8H - 11
PIVOT
SCREW
J898K-22
Fig. 9 Remove Pivot Screw

(27) Install screws that attach housing and shroud Fig. 10 Check Dimmer Switch Rod and Lock Pin
assembly to column jacket and carefully mate hous
CAUTION: When installing a wiper switch, make
ing and shroud assembly. sure wires are laying flat on bottom inside column.
(28) Insert key and lock cylinder and test that the On vehicles equipped with column shift, install
lock pin extends fully when key is moved to lock po PRNDL cable clip with shift indicator on N .
sition. Move selector through the range and make sure
(29) To install remaining parts, reverse the re it lines up with each letter.
moval procedures. (30) Install steering wheel. Tighten steering wheel
nut to 34 N»m (25 ft. lbs.) torque.
J TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
page page
HAZARD LAMPS-XJ 1 TURN SIGNALS-XJ . 1

HAZARD L A M P S - Y J 2 TURN/HAZARD SWITCH REPLACEMENT -
TURN SIGNALS-YJ 2 ALL MODELS 3
TURN SIGNALS—XJ
Refer to Section 8W - Wiring Diagrams for cir (2) Remove and inspect 20 amp TURN fuse. Re
cuit wiring diagram. place if necessary. If OK, go to next step.
(3) Remove turn flasher, light blue can, located in
DESCRIPTION upper left corner of fuse block.
With the turn signal lever in its UP or DOWN po (4) Turn key to ACCY. Check for battery voltage
sition and the ignition key in ACCY or ON, current at flasher bottom cavity on fuse block. If OK, go to
flows through the: next step. If not, repair open circuit in wiring be
• turn/hazard switch tween turn flasher and TURN fuse.
• the selected turn indicator bulb (5) Turn key to ACCY. Move turn signal lever up
• the front and rear bulbs or down. Replace turn flasher with known good
• and the side marker bulb. flasher. The lamps should flash. If not, replace origi
With the headlamps OFF, the turn and side
nal flasher and go to next step.
marker lamps flash in unison. With the headlamps
(6) Turn key to OFF. Follow procedure for turn/
ON, the turn and side marker lamps flash alter
nately. hazard switch replacement to locate steering column
connector. Unplug connector.
DIAGNOSIS-TURN SIGNAL INOPERATIVE (7) Turn key to ACCY. Check for battery voltage
(1) A turn signal indicator arrow that remains lit at connector terminal L. If OK, replace turn/hazard
(without flashing) is usually an indication of a switch and check that lamps flash. If not, repair open
burned out exterior turn signal bulb. Check for and circuit in wiring between turn flasher and steering
replace if defective. System should now function column connector terminal L.
properly. If not, go to next step.
High generator output voltage can burn out
lamps rapidly.
HAZARD LAMPS—XJ
Refer to Section 8W - Wiring Diagrams for cir DIAGNOSIS-HAZARD LAMPS INOPERATIVE
cuit wiring diagram. (1) Inspect 20 amp HAZARD WARNING fuse in
Power Distribution Center (PDC). Replace if neces
DESCRIPTION sary. If OK, go to next step. The PDC is located in
With the hazard switch knob OUT, current flows the engine compartment, passenger side. For location
through the: of fuse, check underside of PDC cover.
• hazard flasher (2) Remove hazard flasher (tin can) located in fuse
• the turn/hazard switch block.
• two front turn signal bulbs (3) Check for battery voltage at the terminal on
• two rear turn signal bulbs the right (3 o'clock). If OK, go to next step. If not, re
• two side marker bulbs pair open circuit in wiring between Hazard fuse and
• and two turn indicator bulbs. hazard flasher right terminal.
All of these bulbs will flash on and off.
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER J
(4) Replace hazard flasher with known good (6) Check for battery voltage at connector terminal
flasher. Activate hazard warning switch. Lamps K. If OK, replace turn/hazard switch and check that
should flash. If not, replace original flasher and go to lamps flash. If not, repair open circuit in wiring be
next step. tween hazard flasher and steering column connector
(5) Follow procedure for turn/hazard switch re terminal K.
placement to locate steering column connector. Un
plug connector.
TURN SIGNALS-YJ
Refer to Section 8W - Wiring Diagrams for cir (2) Remove and inspect 20 amp TURN fuse. Re
cuit wiring diagram. place if necessary. If OK, go to next step.
(3) Remove turn flasher, light blue can, located in
DESCRIPTION fuse block.
With the turn signal lever in its up or down posi (4) Turn key to ACCY. Check for battery voltage
tion and the ignition key in ACCY or ON, current at cavity on left (closest to hazard flasher can). If
flows through the: OK, go to next step. If not, repair open circuit in wir
• turn/hazard switch ing between turn flasher and TURN fuse.
• the selected turn indicator bulb (5) Turn key to ACCY. Move turn signal lever up
• the front and rear turn signal bulbs or down. Replace turn flasher with known good
• and the side marker bulb.
flasher. The lamps should flash. If not, replace origi
With the headlamps OFF, the turn and side
nal flasher and go to next step.
marker lamps flash in unison. With the headlamps
ON, the turn and side marker lamps flash alter (6) Turn key to OFF. Follow procedure for turn/
nately. hazard switch replacement to locate steering column
connector. Unplug connector.
DIAGNOSING—TURN SIGNAL INOPERATIVE (7) Turn key to ACCY. Check for battery voltage
(1) A turn signal indicator arrow that remains lit at connector terminal L. If OK, replace turn/hazard
(without flashing) is usually an indication of a switch and check that lamps flash. If not, repair open
burned out exterior turn signal bulb. Check for and circuit in wiring between turn flasher and steering
replace if defective. System should now function column connector terminal L.
properly. If not, go to next step.
High generator output voltage can burn out
lamps rapidly.
HAZARD LAMP8-YJ
Refer to Section 8W - Wiring Diagrams for cir (3) Check for battery voltage at the terminal on
cuit wiring diagram. the left. If OK, go to next step. If not, repair open cir
cuit in wiring between Hazard fuse and hazard
DESCRIPTION flasher left terminal.
With the hazard switch knob OUT, current flows (4) Replace hazard flasher with known good
through the: flasher. Activate hazard warning switch. Lamps
m hazard flasher should flash. If not, replace original flasher and go to
m the turn/hazard switch next step.
• two front turn signal bulbs (5) Follow procedure for turn/hazard switch re
two rear turn signal bulbs placement to locate steering column connector. Un
two side marker bulbs plug connector.
m and two turn indicator bulbs. (6) Check for battery voltage at connector terminal
All of these bulbs will flash on and off. K. If OK, replace turn/hazard switch and check that
lamps flash. If not, repair open circuit in wiring be
DIAGNOSIS-HAZARD LAMPS INOPERATIVE tween hazard flasher and steering column connector
(1) Inspect 20 amp HAZARD WARNING fuse in terminal K.
Power Distribution Center (PDC). Replace if neces
sary. If OK, go to next step. The PDC is located in
the engine compartment, passenger side. For location
of fuse, check underside of PDC cover.
(2) Remove hazard flasher (tin can) located in fuse
block.
4 TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3
TURN/HAZARD SWITCH REPLACEMENT -ALL MODELS

(1) Disconnect negative cable from battery. LOCKPLATE
(2) Remove the horn button with a push and turn COMPRESSOR
motion.
(3) Remove the horn button components (Fig. 1).
STEERING HORN COLUMN
WHEEL CONTACT
INSULATOR
HORN PAD
FLEX-PLATE
RECEIVER J8919-120
BUSHING
Fig. 2 Lockplate Removal
(13) Remove the screw and hazard warning switch
J9219-54
knob.
(14) Remove dimmer switch actuator arm attach
Fig. 1 Steering Wheel Removal/Installation ing screw (Fig. 3).
(4) Turn key to lock position and remove steering TURN/HAZARD TURN/HAZARD
DIMMER
wheel nut and washer. SWITCH SWITCH ATTACHING SCREW
SWITCH
(5) Scribe an alignment mark on the steering in ACTUATOR
ARM
line with the mark already existing on the end of the SCREW
steering column.
(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.
WARNING: T O REMOVE T H E S T E E R I N G S H A F T
S N A P RING IN T H E FOLLOWING S T E P , T H E LOCK-
P L A T E MUST B E C O M P R E S S E D . DO NOT A T
T E M P T T O REMOVE T H E L O C K P L A T E W I T H O U T
C O M P R E S S O R TOOL C4156 A S THE L O C K P L A T E
IS U N D E R HEAVY SPRING T E N S I O N .
(8) Compress lockplate with compressor tool TURN/HAZARD

C4156. SWITCH ATTACHING
SCREWS J938K-18
card snap ring. It is not reusable. Fig. 3 Turn/Hazard Switch And Dimmer Actuating
(10) Remove the compressor tool. Arm Screws
bearing preload spring.
(12) Remove horn button components from cancel
ing cam.
8J - 4 T U R N S I G N A L S AND H A Z A R D W A R N I N G F L A S H E R — J
(15) Remove turn/hazard switch attaching screws. (20) Remove 2 nuts holding steering column
(16) XJ—Remove lower instrument panel cover bracket to brake sled (Fig. 6),
trim panel. (21) Remove 4 bolts holding steering column
(17) Y J bracket to column.
(a) Remove 6 housing screws (Fig. 4).
* MOUNTING J898K-17
INSTRUMENT
SCREWS
SHROUD J908K-12
Fig. S lower Steering Column
Fig. 4 Instrument Housing Removal/Installation— YJ (22) Loosen column brace mounting nut at drivers
(b) Slide housing toward steering wheel. side kick panel. This will allow column to drop.
(18) Remove cover under column. (23) Push turn/hazard connector up and out of
(19) If vehicle is equipped with a column shift, re steering column connector (Fig. 7).
move PRNDL cable clip (Fig. 5).
J898K-16
Fig. 7 Turn/Hazard Switch And Steering Column
Fig. 5 PRNDL Cable Clip Removal/Installation Connectors
J TURN SIGNALS A I D HAZARD WARNING FLASHER 8J - 5
(24) Pry up locking tabs of steering column connec

tor and remove connector from column bracket.
(25) Tape connector to wires as shown (Fig. 8).
Fig. 9 Remove Plastic Harness Cover

CAUTION: When Installing a turn/hazard switch,
make sure wires are laying flat on bottom inside
Fig. 8 Tape Wiper Switch Connector column.
(26) Remove plastic harness cover by pulling it up
On vehicles equipped with column shift, install
and over the weld nuts then open and slide the cover
the PRNDL cable clip with the shift indicator on
off the harness (Fig, 9).
N (neutral). Move the selector through the range
(27) Remove the turn/hazard switch. Pull the
switch and wire harness straight up and out of the and make sure it lines up with each letter.
housing. (29) Adjust the headlamp dimmer switch as de
(28) To install a new switch, reverse the removal scribed in Group 8L - Lamps.
procedure.
J WINDSHIELD WIPERS 8K - 1
WINDSHIELD WIPERS
CONTENTS
page page
WIPER CONTROL SWITCH REPLACEMENT . . 14 XJ .. 1

WIPER SWITCH TESTING 18 YJ 7
INDEX
page page
Diagnosing Rear Wiper 5 Liftgate Wiper 4
Diagnosing Rear Wiper Washer 6 Liftgate Wiper Switch Replacement 5
Diagnosing Windshield Washer (Intermittent) ..... 4 Rear Wiper/Washer Switch Testing 6
Diagnosing Windshield Washer (Non-Intermittent) . 4 Torque Specifications XJ 6
Diagnosing Windshield Wipers 3 Washer Pump Replacement 2
Front Wipers/Washers 1 Washer Pump Replacement 5
Intermittent Wiper Module 4 Windshield Wiper Motor 2
FRONT WIPERS/WASHERS The wiper motor has an arrangement of brushes

providing the two wiper speeds. When the wipers are
GENERAL turned off, the park switch maintains current to the
Two-speed electric windshield wipers and electric motor until the wipers reach the park position on the
washers are standard equipment. An optional inter windshield.
mittent wiper system provides a pause between wipe The park arm in the motor assembly is connected
cycles for use during conditions of very light precipi to the park switch and is driven by the motor. When
tation. the wiper/washer switch is turned to OFF, current
The windshield wipers can be operated with the flows through the contact and the module to the mo
windshield wiper switch only when the ignition tor until the wipers reach the park position.
switch is in the RUN or ACCESSORY position. A
circuit breaker located in the fuse block protects the CAUTION: T h e wiper arms and blades must not be
circuitry of the wiper system. moved manually from side to side or damage may
result.
WIPERS
The standard windshield wiper circuit contains
three components; wiper/washer switch, motor, and WASHERS
front washer pump. Both standard and intermittent With the washer switch in ON, current flows
circuits are the same, except that the intermittent through the washer pump to ground. The front
circuit requires a module and delay resistance in the washer pump runs as long as the driver holds the
wiper switch. Both circuits receive battery feed from, switch in ON. On standard wipers, the washer switch
and are protected by a 5.5 amp circuit breaker. automatically moves the wiper switch to LO when
In the standard wiper circuit, the switch connects the washer is on. On intermittent wipers, the wiper
the motor directly to battery feed for LO and HI module runs the wiper motor on LO. Turning the
speed operation. In the intermittent circuit, the
switch to OFF stops the wipers.
switch supplies battery feed to the intermittent wiper
If the washer knob is depressed while in the OFF
module, which then supplies the motor. In the delay
position, the module is connected with the variable position, the wiper control will operate for approxi
resistor in the wiper switch. The value of the resis mately 3 wipes and automatically turn OFF.
tance is used by the module to charge a capacitor,
which triggers the amount of delay between wipes.
8K - 2 WINDSHIELD WIPERS
WINDSHIELD WIPER MOTOR (3) Position cowl mounting bracket and install the
attaching nuts. Install pivot pin attaching screws.
REMOVAL Tighten the screws and nuts to 4 N»m (35 in. lbs.)
(1) Remove wiper arm assemblies by lifting blade torque.
off windshield and pulling out on the tab (Fig. 1) to (4) Connect the wire harness.
lock wiper arm in UP position. (5) Connect the washer hose and install cowl trim
panel.
(6) Install the wiper arm assemblies and position
as shown (Fig. 3).
Fig. 1 Wiper Arm Removal

(2) Remove cowl trim panel. Disconnect the washer
hose. Remove the cowl mounting bracket attaching
nuts (Fig. 2) and pivot pin attaching screws.
33-62 MM 23-52 MM
P I V O T PIN S C R E W S (4)
J898K-29
Fig. 3 Windshield Wiper Arm Installation

WASHER PUMP REPLACEMENT
(1) Remove 2 washer reservoir attaching screws
(Fig. 4) and 1 nut (Fig. 5).
J898K-28
Fig. 2 Pivot Assembly Removal

(3) Disconnect wiring harness and remove the as
sembly.
(4) Remove the plastic motor cover.
(5) Remove bolts and nuts holding motor to link
age and remove motor.
The wiper motor is shrouded in a protective
rubber boot. Care should be taken not to punc
ture the boot during removal or installation.
INSTALLATION Fig. 4 Washer Reservoir Upper Attaching Screws

(1) Install motor to linkage.
(2) Install wiper motor and linkage assembly into
the cowl cavity.
WASHER (5) Reverse the removal procedure to install a new

" RESERVOIR pump(s).
LOWER
ATTACHING
NUT DIAGNOSING WINDSHIELD WIPERS
(1) Remove circuit breaker.
• Measure voltage at battery side of the circuit
breaker. Meter should read battery voltage. If not,
repair open to splice.
• Measure resistance across circuit breaker termi
nals. Meter should read zero ohms. If not, replace cir
cuit breaker.
(2) Disconnect wiper switch connector (Non-inter
mittent) or harness side Intermittent Wiper Module
connector.
• Measure the resistance from harness side connec
tor terminal G to ground. Meter should read zero
ohms. If not, repair open to ground.
(3) If equipped with intermittent wipers, turn igni
POWER tion switch to ACCY.
DISTRIBUTION
CENTER J928K-3
CAUTION: DO NOT move the switch to intermittent.
If the switch i s moved to the intermittent position
Fig. 5 Washer Reservoir Lower Attaching Nut
during the next step the rheostat will be damaged.
(2) Disconnect hose from pump(s) (Fig. 6).
FLUID • Remove intermittent wiper module and plug con
LEVEL nectors together from the module. The Wipers should
SENSOR operate in LO and HI speed modes and Mist (washer)
should work. If wipers and Mist now operate, replace
intermittent wiper module. If not, go to step 4.
(4) To test the wiper/washer switch, turn the igni
tion switch to RUN. Position the wiper switch as in
dicated. Back probe switch side of (wiper switch
S E N S O R SEAL
connector for standard), (switch side connector of in
termittent wiper module for intermittent).
• Measure voltage at connector terminal E with
wiper switch in LO and mist/intermittent. Meter
should read battery voltage. If not, replace switch.
FILTER N U T
• Measure voltage at connector terminal C with
wiper switch in HI. Meter should read battery volt
WASHER age. If not, replace switch.
FILTER RESERVOIR • Measure voltage at connector terminal F and move
N U T SEAL wiper switch to OFF. Meter should read battery volt
age until wipers park and then zero volts. If not, re
place switch.
(5) With intermittent wipers, disconnect switch
side of connector of intermittent wiper module.
• Measure resistance across terminals A and D
while rotating switch from minimum delay to maxi
WASHER mum delay. Meter should read 0-500K ohms. If not,
PUMP J928K-4 replace switch.
• Measure resistance across terminals A and G
Fig. 6 Washer Reservoir and Pumps—Typical while rotating switch from minimum delay to maxi
(3) Drain washer reservoir. mum delay. Meter should read 0-500K ohms. If OK,
(4) Using a deep socket, remove filter nut(s) from replace wiper module. If not, replace switch.
(6) To test the wiper motor turn the ignition
bottom inside reservoir and remove pump.
switch to ACCY. Position wiper switch and probe
motor connector as indicated.
8K - 4 WINDSHIELD WIPERS J
• Measure resistance at terminal 1. Meter should WINDSHIELD WIPER CONNECTOR

read zero ohms. If not, repair open to ground.
• Measure voltage at terminal 4 - wiper switch in any 1. B+, PARK FEED (BLUE)
position. Meter should read battery voltage. If OK, re 2. RETURN T O PARK SWITCH
place motor. If not, repair open from fuse panel.
• Measure voltage at terminal 2 - wiper switch in
LO. Meter should read battery voltage. If OK, re
place motor. If not, repair open from wiper switch.
• Measure voltage at terminal 2 - wiper switch in
HI. Meter should read battery voltage. If OK, replace
motor. If not, repair open from wiper switch.
• Measure voltage at terminal 5 - wiper switch to OFF
with voltmeter connected. Meter should read battery
voltage until wipers park and then zero volts. If OK, re
DIAGNOSING W I N D S H I E L D W A S H E R (NON-
INTERMITTENT)
(1) Unplug Washer Pump Connector.
• Measure resistance between terminal A at pump
and a clean chassis ground. Meter should read zero
ohms. If not, repair open to ground. 7. RUBBER PROTECTOR J938K-17
(2) Turn ignition switch to ACCY and washer
switch to ON. LIFTGATE WIPER
• Measure voltage at washer pump connector termi
nal B. Meter should read battery voltage. If OK, re GENERAL
place washer pump. If not, go to next step. The rear wiper motor contains electronic controls
• Measure voltage at wiper washer switch connector to provide three operating modes.
terminal B. Meter should read battery voltage. If OK, • Intermittent wipe with a 5 to 8 second delay be
repair open to washer pump. If not, replace switch. tween sweeps.
• Constant wipe that operates in conjunction with a
DIAGNOSING WINDSHIELD WASHER washer.
(INTERMITTENT) • Park mode that operates when ignition or rear
(1) Unplug Washer Pump Connector. wiper switch is turned off.
©Measure resistance between terminal A at pump The rear wiper switch is located in the instrument
and a clean chassis ground. Meter should read zero panel and is supplied current when the ignition
ohms. If not, repair open to ground. switch is in the ON position. When the switch is
(2) Turn ignition switch to ACCY and washer placed in the intermittent wipe position it provides
switch to ON. current to the rear wiper motor. When it is held in
• Measure voltage at wipe module terminal B (pink the wash/wipe position it provides current to both the
wire). Meter should read battery voltage. If not, re motor and the rear washer pump. The switch is
place wiper switch. spring loaded in the wash/wipe position.
• Measure voltage at wipe module terminal B (violet
REMOVAL
wire). Meter should read battery voltage. If not, re (1) Remove the wiper arm assembly from the pivot
place module. pin by depressing the tab (Fig. 1) and pulling
• Measure voltage at washer pump connector terminal straight out.
B at pump. Meter should read battery voltage. If OK, (2) Slide clip along hose until clip is off hose
replace pump. If not, repair open from Wiper Module. mounting.
(3) Disconnect the washer hose.
INTERMITTENT WIPER MODULE (4) Remove pivot pin retaining nut.
The Intermittent Wiper Module is non-serviceable. (5) Remove external bezel and seal.
Refer to the wiring schematic for connector call outs. (6) Remove the liftgate interior trim panel.
The intermittent wiper module is attached to the (7) Disconnect the wiper motor at the wiring har
lower instrument panel cover near the steering col ness.
umn with a patch of velcro. (8) Remove the wiper motor mounting screws.
(9) Remove the wiper motor.
J WINDSHIELD WIPERS 8K - S
CLIP (7) Install the wiper arm assembly and connect the
WASHER HOSE external washer hose to the bezel.
(8) Slide the clip along the hose until it is over
hose mount.
The blade should be parallel to window open
ing and no closer than 5mm to window seal
when operated on a wet window (Fig. 3).
- j
1
PARKED P O S I T I O N
25 ± 10 M M
FROM MID-POINT O F
J898K-34 BLADE T O W I N D O W SEAL
J898K-36
Fig. 1 Rear Wiper Arm Removal
PIVOT PIN
Fig. 3 Rear Wiper Arm Positioning
RETAINING N U T
WASHER PUMP REPLACEMENT
The washer pump for the liftgate is located next to
the front washer pump on the washer reservoir in
the engine compartment. For replacement refer to
the front washer pump replacement procedure.
LIFTGATE WIPER SWITCH REPLACEMENT

(1) Remove the instrument panel bezel; see Instru
WIPER
ment Panel and Components Section for the proce
MOTOR dure.
(2) Remove the switch housing panel.
(3) Unplug the switch connector. Slightly depress
the switch mounting tabs and remove the switch
(Fig. 4).
DIAGNOSING REAR WIPER

(1) Remove and inspect RR Wipe fuse. Replace as
' MOUNTING required.
SCREWS J928K-5 (2) Remove liftgate cover, turn ignition switch to
ACCY and place wiper switch in WASH.
Fig. 2 Rear Wiper Motor Removal/Installation • Measure resistance between Rear Wiper Relay ter
INSTALLATION minal 2 and terminal 4 (ignition switch off). Meter
(1) Position the motor (Fig. 2) in the liftgate cavity should read zero ohms. If not, repair open to splice in
with the pivot pin protruding through the hole in the body harness.
liftgate. • Measure voltage at Rear Wiper Relay terminal 1
(2) Install the mounting screws. and terminal 5. Meter should read battery voltage. If
(3) Connect the wiring harness. not, go to step 4.
(4) Install the pivot pin, seal, bezel and attaching • Measure voltage at Rear Wiper Relay terminal 3.
nut (Fig. 2). Torque nut to 4 N»m (32 in. lbs.). Meter should read battery voltage. If not, replace re
(5) Connect interior washer hose. lay.
Lubricate the bezel nipples with a small amount (3) Turn ignition switch to ACCY, place wiper
of water and then install the washer hoses. switch in WASH and install relay.
(6) Install the liftgate trim panel.
(3) Remove switch and reconnect below instrument

panel. Backprobe switch connector with ignition
switch in ACCY.
• Measure voltage at switch connector terminal B.
Meter should read battery voltage. If not, repair open
to RR Wipe fuse.
• Measure voltage at switch connector terminal A,
switch in WASH. Meter should read battery voltage.
If not, replace switch.
REAR WIPER/WASHER SWITCH TESTING
A . W I P E R M O T O R F E E D (PARK) C. W A S H E R M O T O R F E E D
B . W I P E R M O T O R F E E D (RUN) D. B A T T E R Y F E E D
J928K-7
Fig. 4 Rear Wiper Switch

c
• Measure resistance between Rear Wiper Motor ter
minal J (ignition switch off). Meter should read zero
ohms. If not, repair open to splice in liftgate harness. REAR W I P E R /
• Measure voltage at Rear Wiper Motor terminal K. SWITCH
S W I T C H DIAGRAM
B WASHER
Meter should read battery voltage. If not, go to step
4. T
• Measure voltage at Rear Wiper Motor terminal H. WASH, , WIPE W A S H 1WIPE

from rear wiper relay terminal 3. r M
4*
(4) Remove switch and reconnect below Instrument J898K-60
panel; back probe switch connector, with ignition key SWITCH TEST
in ACCY position.
• Measure voltage at switch connector terminal B. SWITCH POSITION TERMINALS ZERO OHMS
B AND A NO
to fuse.
OFF (NORMAL)
• Measure voltage at switch connector terminal D.
B AND C NO
Meter should read battery voltage. If OK, repair
open to Rear Wiper Motor terminal K. If not, replace B AND C YES
switch. WIPE
• Measure voltage at switch connector terminal C - BAND A NO
switch in wipe. Meter should read battery voltage. If
OK, repair open to Rear Wiper Relay terminals 1 A AND B YES
and 5. If not, replace switch. WASH
B AND C YES
DIAGNOSING REAR WIPER WASHER J908K-17
(1) Turn ignition switch to ACCY and place rear
wiper/washer switch in WASH. T O R Q U E SPECIFICATIONS XJ
• Operate rear wiper motor. If motor does not oper
Component Torque
ate check the RR Wipe fuse.
(2) Turn ignition switch to ACCY and unplug Rear Front Window Wiper Pivot Screws and Cowl 4 N-m (35 in. lbs.)
Bracket Nut
Washer Pump connector.
• Measure resistance at pump connector terminal A Rear Window Wiper Pivot - Liftgate 5 N-m (44 in. lbs.)
(ignition switch off). Meter should read zero ohms. If Rear Window Wiper Motor Mounting 5 N-m (40 in. lbs.)
not, repair open to ground. Bracket - Liftgate
• Measure voltage at pump connector terminal B, J918K-14
switch in WASH. Meter should read battery voltage.
If OK, replace pump. If not, go to step 3.
YJ
INDEX
page page
Diagnosing Front Windshield Wipers Inoperative . 10 Front Wipers/Washers General Information 7
Diagnosing Intermittent Windshield Washer . . . . . 11 Rear Washer Pump Replacement 11
Diagnosing Non-Intermittent Windshield Washer . 11 Rear Wiper Arm Replacement 11
Diagnosing Rear Wiper/Washer 12 Rear Wiper Motor Replacement . . . . . . . . . . . . . . 12
Front Wiper Arm and Pivot Assembly Replacement . 7 Rear Wiper Switch Replacement . . . . . . . . . . . . . 11
Front Wiper Arm Replacement 7 Rear Wiper/Washer Switch Testing . 13
Front Wiper Blade Replacement .............. 7 Washer Nozzle Replacement 12
Front Wiper Motor 10 Washer Pump Replacement 10
FRONT WIPERS/WASHERS GENERAL W I P E R BLADE

INFORMATION RELEASE
The non-intermittent windshield wiper circuit con
tains three components; control switch, motor and
washer pump. The intermittent circuit contains the
same components and a wiper module that provides
the delay function. Both circuits receive battery feed
from and are protected by a 5.3 amp circuit breaker.
In the non-intermittent wiper circuit, the switch
connects the motor directly to ignition feed for LO
and HI speed operation. In the intermittent circuit,
the switch supplies ignition feed to the delay module,
which then supplies the motor. In the delay position,
the module is connected with the variable resistor in
the wiper switch. The value of the resistance is used
by the solid state module to charge a capacitor,
which triggers the amount of delay between wipes.
The wiper motor has an arrangement of brushes
providing the two wiper speeds. When the wipers are
turned off, the park switch maintains current to the
motor until the wipers reach the park position on the J898K-1
windshield.
The washer pump receives ignition feed either di Fig. 1 Wiper Blade Removal
rectly from the wiper switch or from the intermittent (3) Grasp the wiper arm above the pivot nut.
module. In either case the electric motor will drive (4) Pull and remove the wiper arm assembly.
the washer pump. (5) To install, push the wiper arm over the pivot
The wiper motor is mounted on the lower left cor shaft. Be sure the pivot shaft is in the PARK posi
ner of the windshield. tion and the wiper arm is positioned correctly on the
windshield (Fig. 3).
FRONT WIPER BLADE REPLACEMENT
Rotate the wiper blade release (Fig. 1) clockwise. FRONT WIPER ARM AND PIVOT ASSEMBLY
This will release the wiper blade from the pivot pin. REPLACEMENT
CAUTION: Take Care to ensure that the wiper arm REMOVAL
does not strike the windshield after the wiper blade (1) Remove the left and right wiper arms.
has been removed.
(2) Remove the nuts attaching the pivots to the
To install, place the blade assembly on the wiper windshield frame.
arm and snap the blade assembly into position. (3) Remove the necessary hard or soft top compo
nents from the windshield frame.
FRONT WIPER ARM REPLACEMENT (4) Remove the windshield holddown bolts in the
(1) Pull the wiper arm forward. lower corners of the instrument panel and fold the
(2) Insert an ice pick type tool into the hole (Fig. windshield forward.
2). (5) Remove wiper motor mounting screws (Fig. 4).
GRASP H E R E
Fig. 2 Wiper Arm Removal/Installation

BLADES PARALLEL
108 - 130 mm
(4M - 5% in.) J898K-3
Fig. 3 Wiper Arm Positioning Fig. 5 Disconnect Drive Arm

(6) Disconnect wiper linkage drive arm (Fig. 5). (11) Pry drive arm of the motor pivot. DO NOT re
(7) Remove motor wiring clip from base of wind move pivot attaching nut (Fig. 7).
shield frame.
(8) Remove 4 inboard screws holding seal to bot INSTALLATION
tom of windshield frame (protruding screws ends in (1) Install wiper linkage drive arm onto motor
terfere with pivot link removal and installation). (Fig. 8).
(9) Grasp motor and pull motor and drive arm out (2) Install pivot shaft assembly in windshield
of access hole (Fig. 6). frame.
(10) Remove pivot shaft assembly through access (3) Install motor and drive arm in windshield
hole. frame.
(4) Install weatherstrip screws.
WINDSHIELD WIPERS 8K - 9
Fig. 6 Remove Wiper Motor and Drive Arm Fig. 8 Install Drive Arm On Motor
Fig. 9 Connect Drive Arm To Pivot Shaft

Fig. 7 Drive Arm Removal (8) Install nuts attaching pivots to windshield
(5) Connect wiper linkage drive arm to Pivot Shaft frame. Tighten nuts to 10 N*m (7.5 ft. lbs.).
(Fig. 9). (9) Turn wipers on to allow motor to cycle to Park
(6) Install motor mounting screws. Tighten screws position.
to 10.5 N*m (96 in. lbs.). (10) Install left and right wiper arms (Fig. 3).
(11) Install necessary top components on wind
Be sure wire harness i s not pinched or cut when shield frame.
windshield frame is rotated to upright position.
(7) Raise windshield to upright position and install

left and right windshield holddown bolts.
FRONT WIPER MOTOR

REMOVAL
(1) Remove the necessary hard or soft top compo
nents from the windshield frame.
(2) Remove the windshield holddown bolts in the
lower corners of the instrument panel.
(3) Remove wiper motor mounting screws (Fig. 4).
(4) Remove wiper motor harness retaining clip lo
cated on bottom of windshield.
(5) Disconnect the wiper linkage drive arm (Fig. 5)
(6) Grasp the motor and pull the motor and drive
arm out of the access hole (Fig. 6).
(7) Pry the drive arm of the motor pivot. DO NOT
remove the pivot attaching nut (Fig. 7).
(8) Remove 2 screws holding intermittent wiper
module bracket to bottom of instrument panel.
(9) Reach up behind instrument panel and discon
nect wiper motor harness.
(10) Remove wiper motor.
J918K-4
INSTALLATION
(1) Install wire harness through hole in top of in Fig. 10 YJ Washer Reservoir and Pump
strument panel. DIAGNOSING FRONT WINDSHIELD WIPERS
(2) Connect wiper motor connector behind instru INOPERATIVE
ment panel. Refer to Group 8W - Wiring Diagrams.
(3) Install intermittent wiper module bracket to (1) Turn ignition switch to run or accy. position.
bottom of instrument panel. • Measure voltage at battery side of circuit breaker.
(4) Turn wipers on to allow motor to cycle to Park Meter should read battery voltage. If not, repair open
position. circuit from ignition switch.
(5) Install wiper linkage drive arm onto motor • Measure voltage at wiper side of circuit breaker.
(Fig. 8). Meter should read battery voltage. If not, replace cir
(6) Install motor and drive arm in the windshield cuit breaker.
frame. (2) Measure resistance between motor connector
(7) Connect wiper linkage drive arm to pivot shaft terminal E and clean chassis ground. Meter should
(Fig. 9).
read zero ohms. If not, repair open between motor
(8) Install motor mounting screws. Tighten screws
connector and ground.
to 10.5 N*m (96 in. lbs.).
(9) Install wire harness retaining clip on bottom of INTERMITTENT WIPERS ONLY; If Equipped
windshield. with non-intermittent wipers go to step 4.
(3) Turn ignition switch to run or accy. position.
Be sure wire harness i s not pinched or cut when • Remove intermittent wiper module and plug con
windshield frame i s rotated to upright position. nectors together. Wipers should operate in LO and
HI speed modes and mist (washer) is working. If not,
(10) Raise windshield to upright position and in go to step 5. If wipers and mist now operate, replace
stall left and right windshield holddown bolts. intermittent module.
(11) Install the necessary top components on wind (4) Turn ignition switch to run; wiper switch posi
shield frame. tion as indicated. The tests are made on switch side
of wiper /washer switch connector.
WASHER PUMP REPLACEMENT • Measure voltage at terminal E-switch in LO
(1) Remove 3 washer reservoir mounting screws
and/or mist/intermittent. Meter should read battery
(Fig. 10).
voltage. If not, replace switch.
(2) Disconnect hose(s) from pump.
(3) Drain washer reservoir. • Measure voltage at terminal C-wiper switch in HI.
(4) Using a deep socket, remove filter nut from Meter should read battery voltage. If not, replace
bottom inside reservoir and remove pump. switch.
(5) Reverse the removal procedure to install a new
pump.
J WINDSHIELD WIPERS 8 K - 11
• Measure voltage at terminal F-wiper switch to • Measure voltage at wiper/washer switch connector
OFF with voltmeter connected. Meter should read terminal B located at intermittent wiper module.
battery voltage until wipers park and then zero volts. Meter should read battery voltage. If not, replace
If not, replace switch. wiper switch.
(5) Wiper switch disconnected, turn ignition switch • Measure voltage at intermittent wiper module con
to OFF. nector terminal B (to washer pump). Meter should
• Measure resistance across terminals A and D read battery voltage. If not, replace intermittent
while rotating switch from minimum delay to maxi wiper module.
mum delay. Meter should read from 0-500K ohms. • Measure voltage at washer pump connector termi
• If not, replace switch. nal A. Meter should read battery voltage. If OK, re
• Measure resistance across terminals A and G place pump. If not, repair open from intermittent
while rotating switch from minimum delay to maxi wiper module connector terminal B.
mum delay. Meter should read from 0-500K ohms.
• If not, replace switch. If OK, replace wiper module. REAR WIPER ARM REPLACEMENT
(6) Turn ignition switch to run; wiper switch posi (1) Install Wiper Arm Remover, Snap On A192 or
tion as indicated. Tests are made on motor side of equivalent, on wiper arm (Fig. 11). Lift arm and then
motor connector. remove from output shaft.
• Measure voltage at terminal B-wiper switch in any
CAUTION: Do not use a screwdriver or other prying
position. Meter should read battery voltage. If OK,
tool to remove an arm. T h i s may distort it in a way
replace motor. If not, repair open from fuse panel.
will allow it to come off the pivot shaft in the future
• Measure voltage at terminal A-wiper switch in
despite how carefully it i s installed. N E V E R push or
LO. Meter should read battery voltage. If OK, re
bend the spring clip in the base of the arm in an at
tempt to release the arm. T h i s clip i s self releasing.
• Measure voltage at terminal H-wiper switch in HI.
Meter should read battery voltage. If OK, replace (2) To install, reverse the removal procedure.
motor. If not, repair open from wiper switch.
• Measure voltage at terminal A-wiper switch to
OFF with voltmeter connected. Meter should read
battery voltage until wipers park then zero volts. If
OK, replace motor. If not, repair open from wiper
switch.
DIAGNOSING NON-INTERMITTENT WINDSHIELD

WASHER
Refer to Group 8W - Wiring Diagrams.
(1) Measure resistance from washer pump connec
tor terminal B to a clean chassis ground. Meter
should read zero ohms. If not, repair open between
terminal B and ground.
(2) Turn ignition switch to run and press washer.
• Measure voltage at switch connector terminal B.
Meter should read battery voltage. If not, replace Fig, 11 Removing Liftgate Wiper Arm
wiper/washer switch. (3) Wet the window and check the PARK position
• Measure voltage at washer pump connector termi by operating the wiper motor several times.
nal A. Meter should read battery voltage. If OK, re
place pump. If not, repair open between switch REAR WASHER PUMP REPLACEMENT
connector and pump connector. The washer pump for the rear window is located
DIAGNOSING INTERMITTENT WINDSHIELD next to the front washer pump on the washer reser
WASHER voir in the engine compartment (Fig. 12). For re
Refer to Group 8W - Wiring Diagrams. placement refer to the front washer pump
(1) Measure resistance from washer pump connec replacement procedure.
tor terminal B to a clean chassis ground. Meter
REAR W I P E R SWITCH REPLACEMENT
should read zero ohms. If not, repair open between
terminal B and ground. (1) Remove the instrumentation shroud; see In
(2) Turn ignition switch to run and rotate washer strument Panel, Indicator Bezel Replacement.
switch tab forward. (2) Remove the switch housing panel.
WASHER
RESERVOIR v=^r . W I P E R MOTOR
•V^COVER
1\
ATTACHING
J SCREWS
REAR W A S H E R
PUMP J918K-3
Fig. 12 Rear Washer Pump Fig. 14 Rear Wiper Motor Cover

(3) Unplug the switch connector. Slightly depress MOTOR A N D HINGE
the switch mounting tabs and remove the switch MOUNTING N U T WASHER
HOSE
(Fig. 13).
SWITCH H O U S I N G ELECTRICAL
PANEL CONNECTOR
J928K-6
REAR
WIPER/ Fig. 15 Rear Wiper Motor
WASHER
SWITCH J908K-10 (2) Remove the washer hose from the back of the
washer nozzle.
Fig. 13 Rear Wiper Switch (3) Remove the nut holding the nozzle to the glass.
REAR WIPER MOTOR REPLACEMENT (4) Install the new washer nozzle.
(1) Remove wiper arm from motor (refer to Wiper
DIAGNOSING REAR WIPER/WASHER
Arm Replacement).
Refer to Group 8W - Wiring Diagrams.
(2) Remove pivot shaft retaining nut.
(1) Turn ignition switch to RUN and rear wiper/
(3) Remove motor trim cover (Fig. 14).
washer switch to wash.
(4) Disconnect electrical connector (Fig. 15).
• Measure voltage at switch connector terminal P.
(5) Remove hinge nut holding motor to top.
Meter should read battery voltage. If not, check Rear
Wiper Fuse.
WASHER NOZZLE REPLACEMENT • Measure voltage at switch connector terminal B.
(1) From inside the vehicle remove the motor trim Meter should read battery voltage. If not, replace
cover. switch.
WINDSHIELD WIPERS 8K - 1 3
• Measure voltage at switch connector terminal A. REAR WIPER/WASHER SWITCH TESTING

Meter should read battery voltage. If not, replace
switch. I 1 SWITCH DIAGRAM
(2) Turn ignition switch to RUN and unplug rear
washer pump connector.
• Measure resistance at pump connector black wire
to ground. Meter should read zero ohms (ignition off).
If not, repair open to ground.
• Measure voltage at pump connector brown/white
wire, switch in WASH. Meter should read battery
voltage. If OK, replace pump. If not, check wiring.
(3) Turn ignition switch to RUN, unplug rear REAR VIEW OF
wiper motor connector and place wiper switch in SWITCH
wipe.
• Measure resistance at motor connector terminal B
to ground. Meter should read zero ohms. If not, re
pair open to ground. REAR WIPER
SWITCH
• Measure voltage at motor connector terminal A.
J928K-9
Meter should read battery voltage. If not, check wir
ing to fuse. SWITCH TEST
• Measure voltage at motor connector terminal C. SWITCH POSITION TERMINALS ZERO OHMS
Meter should read battery voltage. If OK, replace
motor. If not, repair open to switch. P AND B NO
O F F (NORMAL)
PANDA NO
P AND B YES
WIPE
PANDA NO
P AND B YES
WASH
PANDA YES
J928K-8
WIPER CONTROL SWITCH REPLACEMENT

(2) Remove horn button with a push and turn mo COMPRESSOR
tion.
STEERING
WHEEL
INSULATOR
HORN P A D
FLEX-PLATE
RECllVER J8919-120
BUSHING
J9219-54
knob.
(4) Turn key to the lock position and remove the TURN/HAZARD TURN/HAZARD
DIMMER SWITCH ATTACHING SCREW
steering wheel nut and washer. SWITCH
SWITCH
(5) Scribe an alignment mark on the steering in ACTUATOR
ARM
line with the mark already existing on the end of the SCREW
steering column.
(6) Remove vibration damper from the steering col
umn hub, if equipped.
(7) Remove steering wheel using a steering wheel
puller. DO NOT hammer on puller or end of steering
shaft.
WARNING: T O R E M O V E T H E S T E E R I N G S H A F T
P L A T E M U S T B E C O M P R E S S E D . DO N O T A T
TEMPT T O R E M O V E THE L O C K P L A T E WITHOUT
C O M P R E S S O R T O O L C4156 A S T H E L O C K P L A T E
I S U N D E R HEAVY S P R I N G T E N S I O N .

SCREWS J938K-18
(10) Remove compressor tool. Arm Screws
bearing preload spring. (15) Remove turn/hazard switch attaching screws
(12) Remove horn button components from cancel (Fig. 3).
(16) XJ Remove lower instrument panel cover trim
ing cam.
panel.
(17) YJ (20) Remove 2 nuts holding steering column

(a) Remove 6 shroud screws (Fig. 4). bracket to brake sled (Fig. 6).
(b) Slide shroud toward steering wheel. Fig. 6 L o w e r steering Column Mounting
(18) Remove cover under column.
22) L o o s e n c o l u m n b r a c e
(19) If vehicle is equipped with a column shift, re- ( mounting nut at drivers
side kick anel This will allow column
ove PRNDL cable clip (Fig. 5). P to drop.
(23) Unplug wiper switch connector.
(24) Tape connector to wires (Fig. 7).
Fig. 7 Tape Wiper Switch Connector

8K - I S WINDSHIELD WIPERS J
(25) Push turn/hazard connector up and out of (29) Insert ignition key in lock cylinder and turn
steering column connector (Fig. 8). key to ON position.
(30) Remove key warning buzzer switch and re
taining clip with a paper clip inserted below retainer
so that retainer is flattened (Fig. 10).
Do not attempt to remove buzzer switch and clip
separately. The clip could fall into the column
jacket.

Connectors
(27) Remove plastic harness cover by pulling it up
and over weld nuts then open and slide the cover off
harness (Fig. 9). Fig. 10 Buzzer Switch Removal
(31) Remove ignition lock cylinder retaining screw
and pull lock cylinder out of column housing (Fig. 11)
KEY/LOCK CYLINDER
Fig. 9 Remove Plastic Harness Cover RETAINING SCREW J8919-125
(28) Pull turn/hazard switch out of column far
enough to allow access to remaining screws. Fig. 11 Lock Cylinder Removal/Installation
J WINDSHIELD WIPERS 8K • 1 7
(32) Remove screws that attach housing and

shroud assembly to column jacket and carefully re
PIVOT
move housing and shroud assembly (Fig. 12). SCREW
Do Not let dimmer switch rod, lock pin or lock
rack fall out.
ATTACHING S C R E W S HOUSING A N D
J898K-22
Fig. 13 Remove Pivot Screw
J908K-11
Fig. 12 Steering Column Housing

(33) Remove turn/hazard/wiper lever by pulling it
straight out of column.
(34) Remove wiper switch cover from back of hous
ing and shroud assembly (Fig. 13). If equipped with
column shift, remove screw holding the cover on.
(35) Remove pivot screw from housing and remove
wiper switch.
(36) Install a new switch and switch cover.
(37) Push on dimmer switch rod to make sure it is
connected then carefully position housing and shroud
assembly to column (Fig. 14).
Make sure nylon spring retainer on lock pin is
positioned forward of the retaining slot of lock
rack (Fig. 14). Fig. 14 Check Dimmer Switch Rod and Lock Pin
Position first tooth of gear (farthest from the CAUTION: When installing a wiper switch, make
block tooth) with the most forward tooth of lock sure wires are laying flat on bottom inside of col
rack. umn.
(38) Install screws that attach housing and shroud
assembly to column jacket and carefully mate hous On vehicles equipped with column shift, install
ing and shroud assembly. PRNDL cable clip with shift indicator on N (neu
(39) Insert key and lock cylinder and test that lock tral). Move selector through the range and make
pin extends fully when key is moved to lock position. sure it lines up with each letter.
(40) To install remaining parts, reverse removal (41) Install steering wheel. Tighten steering wheel
procedures. nut to 34 N»m (25 ft. lbs.) torque.
8K - 18 WINDSHIELD WIPERS < — ^ • ^ J
WIPER SWITCH TESTING

STANDARD WIPER WASHER
B - WASHER PINK
C - HI VIOLET
D - IGNITION WHITE
E - LO/PARK GRAY
F - OFF/PARK YELLOW
WIPER/
WASHER
SWITCH
F E C B
SWITCH TiST
SWITCH POSITION TERMINALS ZERO OHMS

E and F Yes
Off
All Others No
Dand E Yes
Lo
All Others No
CandD Yes
Hi
AH Others No
Band D Yes
Wash DandE Yes
All Others No
J898K-49
J WINDSHIELD W I P E R S 8K - 1 9
INTERMITTENT WIPER WASHER
SWITCH DIAGRAM WIPER/WASHER SWITCH
SWITCH T I S T
EandF Yes
Off
All Others No
Dand E Yes
Lo
All Others No
Cand D Yes
Hi
All Others No
Band D Yes
Wash/Mist Dand E Yes
All Others No
Delay A and G 152-480Kohms
J898K-50
J LAMPS 8L - 1
LAMPS
CONTENTS
page page
EXTERIOR LAMPS 1 SPECIFICATIONS 21

INTERIOR LAMPS . 17
EXTERIOR LAMPS
INDEX
page page
Backup/Rear Turn Signal/Tail Lamp Bulb Headlamp Delay Module Replacement—
Replacement 9 XJ Vehicles 14
Daytime Running Lights (Canada Only) . . . . . . . . 15 Headlamp Dimmer Switch Replacement ........ 6
Drl Module Replacement . . . . . . . . . . . . . . . . . . . 15 Headlamp Switch Replacement . . . . . . . . . . . . . . . 4
Fog Lamp Beam Adjustment , 11 Headlamp Trouble Diagnosis—XJ Vehicles 1
Fog Lamp Bulb/Element Replacement 11
Headlamp Trouble Diagnosis—YJ Vehicles 2
Fog Lamp Replacement . . . . . . . . . . . . . . . . . . . 13
Fog Lamp Service Information 10 License Plate Lamp 10
Fog Lamp Switch Replacement 12 Sentinel Headlamp Delay Module—XJ Vehicles . . 14
Fog Lamp Trouble Diagnosis 10 Service Information 1
Front Park/Turn Signal Lamp Bulb Replacement . . 8 Side Marker Lamp Bulb Replacement . . . . . . . . . . 7
Headlamp Beam Adjustment . . . . . . . . . . . . . . . . . 3 Switch Tests ......... 2
Headlamp Bulb Replacement 3 Underhood Lamp Bulb Replacement 15
Headlamp Delay Function Trouble Diagnosis— Underhood Lamp Replacement 16
XJ Vehicles ... . . . . . . . . . . . 14 Underhood Lamp Service Information . . . . . . . . . 15
SERVICE INFORMATION Next measure between terminal 5 and 7. The ohm

Exterior lamp circuits are comprised of the head meter should indicate zero ohms for both measure
lamp circuit, fog lamp circuit, and tail/side marker/ ments. If not OK, replace the headlamp bulbs.
park lamp circuit. Battery voltage is controlled by (5) Measure the voltage between the dimmer
both the headlamp ON/OFF switch and headlamp switch wire connector terminal 2 and body ground.
dimmer switch. The voltmeter should indicate battery voltage. If not
The dimmer switch functions as a fog lamp switch. OK, continue with the next step.
Voltage is applied to the fog lamp switch only when The dimmer switch is integral with the turn
the dimmer switch is in the low beam position. signal and is located on the steering column.
The dimmer switch switches the headlamp beam
HEADLAMP TROUBLE DIAGNOSIS-XJ VEHICLES when the turn signal lever is pulled rearward.
(6) Disconnect the dimmer switch wire connector
LOW AND HIGH BEAM INOPERATIVE BOTH and place the headlamp switch in the OFF position.
HEADLAMPS Measure the resistance from terminal 2 to vehicle
(1) Place the headlamp switch in the ON position. body ground. The ohmmeter should indicate infinite
(2) Test the 40 amp fuse for continuity. If bad, re resistance. If OK, replace the headlamp switch and
place fuse. continue with the next step. If not OK, repair the
(3) Insert the test probe into terminal 5 of the short circuit in the wire harness that leads to termi
front lamp wire harness connector. Measure the re
nal 2.
sistance from terminal 5 to body ground. The ohm
(7) Measure the resistance from the dimmer switch
meter should indicate zero ohms. If not OK, repair
the open circuit in the harness to body ground. wire harness connector terminal 1 to vehicle body
(4) Disconnect the front lamp wire connector. Mea ground. The ohmmeter should indicate zero ohms. If
sure resistance between connector terminals 5 and 2.
8L - 2 LAMPS J
OK, continue with the next step. If not OK, repair body ground. The voltmeter should indicate battery
the short circuit in the wire harness that leads to voltage. If not OK, repair the open circuit in the wire
terminal 1. harness between the fuse and the switch connector
(8) Measure the resistance from the dimmer switch terminal.
wire harness connector terminal 3 to vehicle body (3) Measure the voltage between the headlamp
ground. The ohmmeter should indicate zero ohms. If switch connector battery voltage OUT terminal and
OK, test the dimmer switch. Replace, if defective. vehicle body ground. The voltmeter should indicate
Connect the wire harness connector to the dimmer battery voltage. If not OK, replace the headlamp
switch. If not defective, repair the short circuit in the switch.
wire harness that leads to terminal 3
DIMMER SWITCH-ALL VEHICLES
LOW OR HIGH BEAM INOPERA TIVE BOTH (1) Place the headlamp switch in the ON position.
HEADLAMPS Place the dimmer switch in the HIGH or LOW beam
(1) Place the headlamp switch in the OFF position. position, as applicable.
Disconnect the dimmer switch wire harness connec (2) Measure the voltage between the dimmer
tor. switch connector voltage supply terminal and vehicle
(2) Measure the resistance from the dimmer switch body ground. The voltmeter should indicate battery
connector terminal 1 to body ground. The ohmmeter voltage. If not OK, repair the open circuit in the wire
should indicate zero ohms. If not OK, repair the open harness between the headlamp switch and the dim
circuit in the wire harness that leads to the head mer switch.
lamp bulbs.
(3) Measure the resistance from the dimmer switch
connector terminal 3 to vehicle body ground. The
ohmmeter should indicate zero ohms. If OK, replace
the dimmer switch. If not OK, repair the open circuit
in the wire harness that leads to headlamp bulbs.
HEADLAMP T R O U B L E D I A G N O S I S - Y J VEHICLES
(1) Place the headlamp switch in the ON position.
(2) Place the headlamp dimmer switch in the
HIGH or LOW position.
(3) Disconnect the wire harness connectors from
the headlamp bulbs.
(4) If applicable, measure voltage between each
headlamp bulb wire connector terminal B and vehi
cle body ground. The voltmeter should indicate bat
tery voltage. If not OK, repair the open circuit in 1. H I G H BEAM
2. LOW BEAM
wire harness between connector and dimmer switch. 3. HEAD LAMP FEED (FROM LAMP SWITCH)
(5) If applicable, measure the voltage between each 4. FEED FROM HEADLAMP SWITCH TOR FLASH T O PASS
headlamp bulb connector terminal C and body
ground. The voltmeter should indicate battery volt
J89SL-70
age. If not OK, repair the open circuit in the wire
harness between the connector and the dimmer
switch. Fig. 1 Headlamp Dimmer Switch Terminals
(6) Measure the resistance from each headlamp (3) Place the dimmer switch in the LOW beam po
bulb connector terminal A to body ground. The ohm sition. Measure the voltage between the dimmer
meter should indicate zero ohms. If not OK, repair switch connector low beam voltage OUT terminal
the open circuit in the wire harness between the con and body ground. The voltmeter should indicate bat
nectors and vehicle body ground. tery voltage. If not OK, replace the dimmer switch.
(4) Place the dimmer switch in the HIGH beam po
SWITCH TESTS
sition. Measure the voltage between the dimmer
HEADLAMP-ALL VEHICLES switch connector high beam voltage OUT terminal
(1) Refer to the applicable wiring diagram for ter and body ground. Voltmeter should indicate battery
minal reference. voltage. If not OK, replace dimmer switch.
(2) Place the headlamp switch in the ON position.
(2) Measure the voltage between the headlamp
switch connector voltage supply terminal and vehicle
LAMPS 8L - 3
J
HEADLAMP BULB REPLACEMENT INSTALLATION
(1) Position the bulb in the bucket and connect the
REMOVAL wire harness connector.
(1) Remove the screws and the headlamp bezel (2) Position retaining ring on the headlamp bulb
(Figs. 2 and 3). and install screws.
(3) Install the headlamp bezel. Tighten the screws
securely.
HEADLAMP BEAM ADJUSTMENT

SERVICE INFORMATION
The following headlamp beam adjustment proce
dures apply to all Jeep® vehicles. The headlamp
beam must be adjusted with the headlamps on LOW
beam. The headlamp beam can be adjusted either
with the use of mechanical headlamp aimers or by
the use of an aiming screen (Fig. 4).
1. Headlamp Bezel
2. Headlamp Retaining Ring
3. Headlamp
4. Headlamp Bucket
5. Retaining Ring Screws (4)
J918L-5
Fig. 2 Headlamp Components—XJ Vehicles
2 4
1. H E A D L A M P A L I G N M E N T S C R E E N
2. 2 5 F E E T F R O M S C R E E N
7
3. L A M P H O R I Z O N T A L C E N T E R L I N E (TAPE)
4. R I G H T L A M P V E R T I C A L C E N T E R L I N E (TAPED)
5 . L E F T L A M P V E R T I C A L C E N T E R L I N E (TAPE)
6. V E H I C L E C E N T E R L I N E
918L-25
Fig. 4 Headlamp 'Aiming" Screen
ADJUSTMENT WITH MECHANICAL AIMERS
Use Headlamp Aimer C-4466-A (J25300-A) and fol
Plastic Adjuster Nut(s) low instructions supplied with equipment.
Adjusting Screw(s) Adjust headlamps so that the beam horizontal po
Headlamp Bucket sition is at 0 and beam vertical position is 25 mm (1
Adjusting Spring in) downward.
Headlamp
Retaining Ring ADJUSTMENT WITH AIMING SCREEN
Trim Ring
Trim Ring Screws (4)
Retaining Ring Screws (4) PREPARATION
J918L-6
When an aiming screen is to be used for headlamp
aim adjustment, use following procedure.
Fig. 3 Headlamp Components— YJ Vehicles (1) Position the vehicle in dark area with a level floor
and with a screen (wall) that has a white surface.
(2) Remove the screws and headlamp bulb retain
(2) Refer to Figure 4. Mark a reference line (2) on
ing ring. the floor 7.62 meters (25 feet) away from and parallel
(3) Disconnect the headlamp bulb wire harness to the screen/wall (1).
connector and remove the bulb from the bucket. (3) Move vehicle with the headlamps located di
rectly above the 7.62-meters (25-feet) reference line.
8L - 4 LAMPS J
(4) Equalize all the tire pressures. V E R T I C A L (TAPED) * ACCEPTABLE ALIGNMENT RANGE -
(5) Rock vehicle from side to side to stabilize the CENTERLINE AHEAD ALL DIMENSIONS ARE IN
springs and shock absorbers. OF LEFT HEADLAMP INCNES AT 25 FEET
(6) Use tape to attach a vehicle centerline on the ^ VEHICLE (TAPED)
screen/wall (6). Ensure that it is aligned with and T O P E D G E O F LAMP CENTERLINE
HIGH I N T E N S I T Y Z O N E I
represents the centerline of the vehicle. M U S T BE W I T H I N INSPECT RIGHT LAMP
(7) Measure distance between the vehicle headlamp THIS AREA SAME A S LEFT
centers. Divide this distance by two. Measure the one/
half distance outward from each side of the vehicle cen
terline (6). Use tape to attach the right and left lamp
vertical centerline (4 and 5) on the screen/wall (6). LAMP H O R I Z O N T A L
C E N T E R L I N E (TAPED)
(8) Measure the distance from the center of each
headlamp to the floor.
(9) Measure the lamp-to-floor distance upward
from the floor at each lamp vertical centerline (4 and
5). Use tape to attach the lamp horizontal centerline
(3) on the screen/wall. L E F T E D G E O F LAMP
V E R T I C A L (TAPED) C E N T E R L I N E
HIGH INTENSITY Z O N E
AHEAD O F RIGHT HEADLAMP
ADJUSTMENT M U S T BE W I T H I N
THIS AREA
(1) Remove screws and both headlamp bezels.
LOW BEAMS ONLY
(2) Clean front of the headlamps. 918L-27
(3) Place headlamps on LOW beam. Fig. 6 Headlamp Beam Pattern—Typical
(4) Cover front of the headlamp that is not being
(8) Install headlamp bezels. Tighten the screws se
adjusted.
(5) Turn vertical adjustment screw until the head curely.
lamp beam pattern on screen/wall is similar to the
pattern depicted in Figure 6. HEADLAMP SWITCH REPLACEMENT
HEMOVAL-XJ VEHICLES
(1) Disconnect battery negative cable.
(2) Place headlamp switch control knob in the
headlamp ON position.
(3) Depress the switch shaft release/retainer but
ton via the underside of the instrument panel. Pull
the switch control shaft knob outward.
P U S H RETAINER B U T T O N
1. H O R I Z O N T A L A D J . S C R E W - R H
2. VERTICAL A D J . SCREW
3. H O R I Z O N T A L A D J . SCREW - L H
J908L-24
Fig. 5 Headlamp Beam Adjustment Screws—XJ/YJ

Vehicles
When using a headlamp aiming screen:
• adjust the headlamps so that the beam horizontal
position is at 0; and
• adjust the beam vertical position is 25 mm (1 in)
downward from the lamp horizontal centerline.
(6) Rotate the horizontal adjustment screw until
the headlamp beam pattern on the aiming screen/
wall similar to the pattern in Figure 6.
(7) Cover front of the headlamp that has been ad VIEWED F R O M UNDERSIDE OF D A S H
J898L-13
justed and adjust the other headlamp beam as in
structed above. Fig. 7 Headlamp Switch Shaft Removal-XJ Vehicles
J LAMPS 8L - §
(4) Remove the headlamp switch spanner nut from (4) Apply upward force to the I/P shroud and
the front of the instrument panel (Fig. 8). downward force to the indicator panel. This will re
lease the indicator panel holding tabs (Fig. 10).
HEADLAMP RELEASE
SWITCH BUTTON
KNOB
- • — M O U N T I N G BRACKET
SWITCH
B-fe-TINNERMAN NUT
BEZEL 898E-42
Fig. 8 Headlamp Switch—Typical

(5) Disconnect the wire harness connector from the
switch.
(6) Remove the headlamp switch from the instru
ment panel.
INSTALLM TION—XJ VEHICLES

(1) Install the headlamp switch in the instrument HOLDING TABS
panel and connect the wire harness connector. J898K-15
(2) Install the headlamp switch spanner nut.
(3) Insert the headlamp switch control shaft in the Fig. 10 Indicator Panel Holding Tabs—YJ Vehicles
spanner nut and force it into the switch. (5) Remove the shroud from the instrument panel.
(4) Connect the battery negative cable. (6) Remove the headlamp switch retaining screws
(Fig. 11).
REMOVAL—YJ VEHICLES
(1) Disconnect the battery negative cable.
(2) Remove the I/P shroud retaining screws (Fig. 9).
•MOUNTING,
SCREWS
J898L-15
INSTRUMENT 'MOUNTING/
SCREWS Fig. 11 Headlamp Switch—YJ Vehicles
SHROUD J908K-12
(7) Disconnect the headlamp switch wire harness
Fig. 9 Instrument Panel Shroud—YJ Vehicles connector.
(8) Remove the headlamp switch from the instru
(3) Move the I/P shroud toward the steering wheel.
ment panel cavity.
8L - 6 LAMPS J
INSTALLA TION- YJ VEHICLES

(1) Position headlamp switch in the instrument
panel and connect the wire harness connector to the
switch.
(2) Install the headlamp switch screws. Tighten
the screws.
(3) Position the I/P shroud under the steering col
umn.
(4) Slide the indicator panel holding tabs into the
shroud notches.
(5) Place the assembled I/P shroud over the indica
tor lamp gasket.
(6) Install and tighten the indicator panel screws.
(7) Install the remaining shroud screws. Tighten
the screws.
(8) Connect the battery negative cable.
HEADLAMP DIMMER SWITCH REPLACEMENT
REMOVAL
(2) Remove the lower instrument panel (Fig. 12)
and continue with step 4.
LOWER INSTRUMENT
PANEL J 9 0 8 W
Fig. 12 Lower Instrument Panel—XJ Vehicles

(3) Y J vehicles:
• remove the I/P shroud retaining screws (Fig. 13).
• move the I/P shroud toward the steering wheel;
• apply upward force to the I/P shroud and down
ward force to the indicator panel — this will release Fig. 14 Indicator Panel Holding Tabs—YJ Vehicles
the indicator panel holding tabs (Fig. 14); (5) Tape the dimmer switch actuator rod to the
• remove the shroud from the instrument panel; steering column.
• support the A/C evaporator housing; (6) Remove the dimmer switch screws and detach
• remove the A/C evaporator housing-to-instrument
the switch from the rod.
panel screws (Fig. 15);
• remove the A/C evaporator housing support INSTALLATION
bracket screw; (1) Force the dimmer switch onto the actuator rod
• remove the support and lower the A/C evaporator and install screws. DO NOT tighten the retaining
housing; and
screws at this time.
• continue with step 4.
(2) Remove the tape attaching the actuator rod to
(4) Disconnect the dimmer switch wire harness
the steering column.
connector.
J LAMPS 8L - 7
EVAPORATOR H O U S I N G • install and tighten remaining shroud screws;

M O U N T I N G SCREWS • raise and support the A/C evaporator housing (Fig.
15); and
• install the evaporator housing-to-instrument panel
screws and evaporator support bracket screw.
SIDE MARKER LAMP BULB REPLACEMENT
REMOVAL-MJ VEHICLES
(1) Remove the screws from the side marker lamp
lens and housing. Separate lens and housing from
J8924-77"
the headlamp bezel (Fig. 17).
Fig. 15 A/C Evaporator Housing—YJ Vehicles
(3) Adjust the dimmer switch as follows:
• compress the switch and insert a 3/32-inch diame
ter drill bit into the adjustment hole (Fig. 16);
• the drill bit will prevent any horizontal movement
of the switch;
IGNITION
SWITCH
ADJUSTMENT
HOLE
J898L-19
Fig. 17 Side Marker Lamp—XJ Vehicles

(2) Remove the bulb and socket from the back side
of the lamp housing.
(3) Remove bulb from socket.
INSTALLA TION—MJ VEHICLES

(1) Install a replacement bulb in the socket.
(2) Install bulb and socket in the back of side
DIMMER
SWITCH
J8919-116 marker lamp housing.
(3) Position the side marker lens and housing on
Fig. 16 Headlamp Dimmer Switch Adjustment the headlamp bezel (Fig. 17).
• move the switch toward the steering wheel to re (4) Install the side marker lamp screws. Tighten
move any existing actuator rod lash; the screws.
• tighten screws with 4 N*m (35 in. lbs.) torque.
REMOVAL— YJ VEHICLES
• connect battery negative cable;
(1) Remove side marker bulb socket via the under
• remove drill bit and test the switch operation; and
side of the fender. Rotate it one-third turn and sepa
• re-adjust the switch, if necessary.
(4) XJ vehicles — install the lower instrument rate it from the side marker lamp housing (Fig. 18).
panel (Fig. 12) (2) Remove the bulb from the socket by pulling it
(5) Y J vehicles: straight outward.
• position the I/P shroud under the steering column;
INSTALLA TION- YJ VEHICLES
• slide the indicator panel holding tabs (Fig. 14) into
the shroud notches; (1) Install a replacement bulb in the socket.
• place the assembled I/P shroud over the indicator (2) Install the bulb and socket in the side marker
lamp gasket; lamp housing (Fig. 18).
• install and tighten screws;
8L - 8 LAMPS J
J908L-2
Fig. 18 Side Marker Lamp Bulb—YJ Vehicles

FRONT PARK/TURN SICNAL LAMP BULB
REPLACEMENT
J918L-14
REMOVAL XJ VEHICLES
(1) Remove the headlamp bezel screw and the side
marker lamp lens/housing screw (Fig. 19). Fig. 20 Headlamp Bezel Removal/Installation
Fig. 21 Park/Turn Signal Lamp Housing Removal

(6) Remove bulb from socket.
INSTALLA TION—XJ VEHICLES

(2) Install bulb and socket in the lamp housing.
(3) Position the park/turn signal lamp housing on
Fig. 19 Headlamp Bezel & Side Marker Lamp—XJ the headlamp bezel.
Vehicles (4) Install lamp housing screws. Tighten the
(2) Separate the side marker lamp from the head screws.
lamp bezel and remove the screws from the head (5) Install the outer screws in the headlamp bezel.
lamp bezel (Fig. 20). Tighten the screws.
(3) Remove screws from the park/turn signal lamp (6) Position the side marker lamp lens/housing on
housing (Fig. 21). the headlamp bezel.
(4) Separate the lamp housing from the headlamp (7) Install side marker lamp lens/housing screws
bezel. and headlamp bezel (Fig. 19). Tighten the screws.
(5) Rotate the bulb socket one-third turn and re
move it from the lamp housing.
J LAMPS 8L - i
REMOVAL-YJ VEHICLES
(1) Remove the park/turn signal lamp housing
screws (Fig. 22).
Fig. 23 Tail Lamp Housing—XJ Vehicles
Fig. 22 Park/Turn Signal Lamp Bulb

Replacement— YJ Vehicles
(2) Separate the park/turn signal lamp housing
from the grille panel.
move it from the lamp housing.
(4) Remove the bulb from the socket.
INSTALLATION- YJ VEHICLES
(2) Install the bulb and socket in the lamp hous
ing.
(3) Position the park/turn signal lamp housing at
the opening in the grille panel. Fig. 24 Bulb Socket Removal—XJ Vehicles
(4) Install the lamp housing retaining screws.
Tighten the screws securely. REMOVAL-YJ VEHICLES
(1) Remove the lens retaining screws from the tail
BACKUP/REAR TURN SIGNAL/TAIL LAMP BULB lamp housing (Fig. 25).
REPLACEMENT
REMOVAL—XJ VEHICLES
(1) Remove the tail lamp housing upper retaining
screws. Slide the lamp housing upward off the lower
screw and separate it from the rear of the vehicle.
move the bulb socket from the lamp housing.
(3) Remove the bulb from the socket.
INSTALLA TION—XJ VEHICLES

(2) Install the bulb and socket in the lamp hous
ing.
(3) Position the lamp housing in the opening at the
rear of the vehicle.
(4) Install the lamp housing screws. Tighten the Fig. 25 Backup/Rear Turn Signal/Tail Lamp Bulb
screws securely. Replacement— YJ Vehicles
8L - 10 LAMPS J
(2) Separate the lens from the tail lamp housing. FOG LAMP TROUBLE DIAGNOSIS
(3) Remove the bulb from the lamp socket.
ONE FOG LAMP INOPERATIVE
INSTALLA TION— YJ VEHICLES (1) Place the headlamp switch in the full ON posi
(1) Install a replacement bulb in the lamp socket. tion, the dimmer switch in the LOW beam position
(2) Position the lens on the lamp housing. and the fog lamp switch in the ON position.
(3) Install the lens retaining screws. Tighten the (2) Disconnect the applicable fog lamp wire har
screws securely. ness connector (Fig. 27).
LICENSE PLATE LAMP FOG WIRE
REMOVAL-KJ VEHICLES
(1) Remove screws and the license plate lamp visor
from the liftgate (Fig. 26).
LICENSE PLATE BULB
HOUSING
J9223-53
Fig. 27 Fog Lamp & Wire Harness Connector—XJ

Vehicles
(3) Measure the resistance between the lamp con
nector terminals. The ohmmeter should indicate zero
ohms. If not OK, replace the bulb.
(4) Measure the resistance between the wire har
ness connector ground terminal and vehicle body
ground. The ohmmeter should indicate zero ohms. If
not OK, repair the open circuit in the wire harness
J898L-35 to vehicle body ground.
(5) Measure the voltage between the wire harness
Fig. 26 License Plate Lamp Visor connector voltage supply terminal and body ground.
The voltmeter should indicate battery voltage. If not
(2) Remove the bulb from the lamp socket.
OK, repair the open circuit in the wire harness that
INSTALLATION- MJ VEHICLES leads to the source of battery voltage.
(1) Install a replacement bulb in the lamp socket. BOTH FOG LAMPS INOPERATIVE
(2) Position the license plate lamp visor on the lift (1) Place headlamp switch in the full ON position.
gate and install screws. Tighten the screws securely. The dimmer switch in the LOW beam position. The
fog lamp switch in the ON position.
FOG LAMP SERVICE INFORMATION (2) Measure the voltage between the fog lamp
Fog lamps can be operated ONLY when the head switch wire harness connector terminal B and vehi
lamps are on LOW beam. If the headlamps are cle body ground. The voltmeter should indicate bat
switched to HIGH beam, the fog lamps will not oper tery voltage. If not OK, repair the open circuit in the
ate. wire harness that leads to the headlamp dimmer
Also, the fog lamps ON display on the switch will: switch circuit.
• be illuminated when the headlamps are switched (3) Measure the voltage between the fog lamp
to LOW beam; and switch connector terminal C and vehicle body
• be extinguished when the headlamps are switched ground. The voltmeter should indicate battery volt
to HIGH beam. age. If not OK, replace the fog lamp switch.
(4) Measure the voltage between the fog lamp re
lay connector terminal 1 and vehicle body ground.
The voltmeter should indicate battery voltage. If not
J LAMPS 8L-11
OK, repair the open circuit in the wire harness that (8) Measure the distance from the center of each
leads' to the power distribution center/PDC. fog lamp to the floor.
(5) Measure the voltage between the fog lamp re (9) Measure the lamp-to-floor distance upward
lay connector terminal 5 and vehicle body ground. from the floor at each lamp vertical centerline. Use
The voltmeter should indicate battery voltage. If not tape to attach the lamp horizontal centerline on the
OK, repair the open circuit in the wire harness that screen/wall.
leads to the fog lamp switch.
(6) Measure the voltage between the fog lamp re BEAM ADJUSTMENT
lay connector terminal 2 and vehicle body ground. (1) Loosen the fog lamp attaching hardware at the
.The voltmeter should indicate battery voltage. If not support bracket.
OK, repair the open circuit in the wire harness that (2) Place the headlamp and fog lamp switches in
leads to vehicle body ground. the ON position.
(7) Measure the voltage between the fog lamp re (3) Ensure that the headlamp dimmer switch is in
lay connector terminal 4 and vehicle body ground. the LOW beam position.
The voltmeter should indicate battery voltage. If not (4) Adjust the fog lamp beams according to the fol
OK, replace the relay, lowing guidelines:
• a properly adjusted fog lamp (up/down adjustment)
FOG LAMP BEAM ADJUSTMENT will project a beam pattern on the screen similar to
Use an "aiming" screen for fog lamp beam aim ad the pattern depicted in Figure 28; and
justment. • each fog lamp should be centered (left/right adjust
ment) on the screen left/right vertical center line.
PREPARATION
Prior to adjustment, the following preparation is (5) Tighten the fog lamp support bracket hard
required. ware.
(1) Position the vehicle in dark area with a level
floor and with a screen (wall) that has a white sur FOG LAMP BULB/ELEMENT REPLACEMENT
face. REMOVAL
(2) Mark a reference line on the floor 7.82 meters (1) For YJ vehicles, remove the screws that attach
(25 feet) away from and parallel to the "aiming"
the stone shield and the reflector to the lamp hous
screen/wall.
ing. Remove the stone shield and reflector from the
(3) Position vehicle with the fog lamps located di
lamp housing (Fig. 29).
rectly above the 7.62-meters (25-feet) reference line.
(4) Equalize all the tire pressures.
(5) Rock the vehicle from side to side to stabilize
the springs and shock absorbers.
(6) Refer to Figure 28. Use tape to attach a vehicle
centerline on the screen/wall. Ensure that it is
aligned with and represents the centerline of the ve
hicle.
r~—~
VERTICAL C E N T E R LINE CEh VERTICAL C E N T E R LINE
ITER
A H E A D OF L I F T C AHEAD OF RIGHT
W SCREW
FGGiAMPv VEr FOG LAMP
IICLE
\ /
HORIZONTAL CENTER
SJNE OF P3GLAAAPS
STONE LENSE/ HALOGEN
4 B
BELOW | SHIELD REFLECTOR BULB J928L-10
Fig. 29 Fog Lamp—YJ Vehicles

high ghfiPr- ' (2) For XJ vehicles, remove the screws that attach
ABEA 898L-4
the bezel and lens to the lamp housing. Remove the
bezel and the lens from the lamp housing (Fig. 30).
Fig. 28 Fog Lamp Beam Pattern (3) Remove the bulb/element holder from the lens/
(7) Measure the distance between the vehicle fog reflector.
lamp centers. Divide this distance by two. Measure (4) Remove the bulb/element from the holder.
the one/half distance outward from each side of the
vehicle centerline. Use tape to attach the right and
left fog lamp vertical centerline on the screen/wall.
8L - 1 2 LAMPS J
BEZEL SNAP FIT

ATTACHING LOCATION
SCREWS N
ELEMENT BRACKET J928L-12

LOCATIONS
Fig. 30 Fog Lamp—XJ Vehicles
Fig. 31 Instrument Panel Bezel—XJ Vehicles
REMOVAL
REMOVAL-YJ VEHICLES
CAUTION: Always handle replacement quartz bulbs/ The fog lamp switch is located on the instrument
elements with a clean cloth. DO NOT handle quartz panel at the right of the steering column. The fog
bulbs/elements with bare hands. lamp circuit relay is located below the left headlamp.
(1) Use a clean cloth to install a replacement bulb (2) Remove the I/P shroud retaining screws (Fig.
holder. 32).
(2) Install the bulb holder in the lens/reflector.
(3) For XJ vehicles, position the bezel and the lens
on the lamp housing. Install the screws that attach
the bezel and lens to the lamp housing. Tighten the
screws securely.
(4) For YJ vehicles, 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.
FOG LAMP SWITCH REPLACEMENT
REMOVAL-XJ VEHICLES
The fog lamp switch is located on the instrument
panel at the left of the steering column.
(1) Remove instrument panel bezel attaching
screws and remove the bezel (Fig. 31).
(2) Remove the fog lamp switch cover.
switch.
SHROUD J908K-12
(4) Squeeze the tabs on the side of the switch and
remove the switch from the instrument panel cavity. Fig. 32 Instrument Panel Shroud— YJ Vehicles
INSTALLA TION—XJ VEHICLES (3) Move the I/P shroud toward the steering wheel.
(1) Squeeze the tabs on the side of the fog lamp (4) Apply upward force to the I/P shroud and
switch and insert the switch in the instrument panel downward force to the indicator panel. This will re
cavity. lease the indicator panel holding tabs (Fig. 33).
(2) Connect the wire harness connector to the (5) Remove the shroud from the instrument panel.
switch. (6) Remove the fog lamp switch retaining screws.
(3) Install the fog lamp switch cover. (7) Disconnect the wire harness connector from the
(4) Position the bezel on the instrument panel and fog lamp switch.
install the attaching screws. Tighten the screws se (8) Remove the fog lamp switch from the instru
curely. ment panel cavity.
lamps SL -13
FOG WIRE
LAMP HARNESS
CONNECTOR
FRONT
BUMPER
RAIL
J9223-53
Fig. 34 Fog Lamp Wire Harness Connector—XJ

Vehicles
BOLTS AND WASHERS
HOLDING TABS FOR LAMP REMOVAL/ADJUSTMENT
J898K-15
Fig. 33 Indicator Panel Holding Tabs—YJ Vehicles

INSTALLA TION— YJ VEHICLES
(1) Position the fog lamp switch in the instrument
panel cavity and connect the wire harness connector
to the switch.
(2) Install the fog lamp switch retaining screws.
Tighten the screws securely.
(3) Position the I/P shroud under the steering col
umn.
(4) Slide the indicator panel holding tabs into the
shroud notches.
(5) Place the assembled I/P shroud over the indica
tor lamp foam gasket.
The foam gasket located on the back side of
the indicator panel overlay is fragile. If it is ei
ther torn or distorted, replace it. J898L-37
(6) Install and tighten the indicator panel retain
ing screws. Fig. 35 Fog Lamp—XJ Vehicles
(7) Install the remaining shroud screws. Tighten (2) Connect the fog lamp wire harness connector.
the screws securely.
(8) Connect the battery negative cable. REMOVAL—YJ VEHICLES
(1) Disconnect the fog lamp wire harness connec
FOG LAMP REPLACEMENT tor.
(2) Remove the fog lamp nut(s), washers(s) and
REMOVAL XJ VEHICLES
bolt(s) from the support bracket.
(1) Disconnect the fog lamp wire harness connector
(3) Remove the fog lamp from the support bracket.
(Fig. 34).
(2) Remove the retaining nut and washer from INSTALLA TION— YJ VEHICLES
each side of the support bracket and remove the fog
(1) Position the fog lamp on the support bracket.
lamp from the support bracket (Fig. 35).
(2) Install the fog lamp bolt(s), washer(s) and
INSTALLA TION—XJ VEHICLES nut(s) in the support bracket.
(1) Position the fog lamp in the support bracket (3) Connect the fog lamp wire harness connector.
and install the washer and nut at each side of the
bracket. Tighten the nuts securely.
8L - 1 4 LAMPS
J
switch is turned OFF. The driver engages the module
by turning the ignition switch OFF, then turning the
headlamps OFF.
The headlamp delay module is located behind the
I/P next to the headlamp switch.
HOUSING
HEADLAMP DELAY MODULE REPLACEMENT—XJ
VEHICLES
The headlamp delay module is attached to the in
SCREW side of the instrument panel to the right of the head
lamp switch.
REMOVAL
STONE LENSE/ HALOGEN
SHIELD REFLECTOR BULB J928L-10 (1) Remove the lower instrument panel.
(2) Remove the screw that attaches the module to
Fig. 36 Round-Shaped Fog Lamp the inside of the instrument panel.
(3) Disconnect the wire harness connector and re
move the module from the instrument panel.
REFLECTOR
INSTALLATION
LENSE
(1) Position the module inside the I/P and connect
the wire harness connector to the module.
(2) Install the screw that attaches the module to
the inside of the instrument panel.
(3) Remove the lower instrument panel.
HEADLAMP DELAY FUNCTION TROUBLE

D I A G N O S I S - X J VEHICLES
SUPPORT
DELAY FUNCTION INOPERATIVE
ELEMENT BRACKET J928L-12 (1) Remove, inspect and test the HD LP DLY fuse.
Replace if defective.
Fig. 37 Rectangular-Shaped Fog Lamp (2) Remove the delay module from the I/P. Do not
FENDER disconnect the wire harness connector. Turn the igni
EXTENSION BOLT tion switch to the RUN position. Place the headlamp
PANEL switch in headlamps ON position. Turn the ignition
to the OFF position for a resistance test.
(3) Measure the resistance from the delay module
terminal 4 to vehicle body ground. The ohmmeter
should indicate zero ohms. If not, repair the open cir
cuit in the wire harness to vehicle body ground.
(4) Measure the voltage between the delay module
terminal 8 and vehicle body ground. The voltmeter
should indicate battery voltage. If not, repair the
PUSH- open circuit in the wire harness to the instrument
ON N U T
cluster indicator connector terminal 14.
NUT (5) Measure the voltage between the delay module
U-NUT BOLT J9123-513
should indicate battery voltage. If not, repair the
Fig. 38 Fog Lamp—YJ Renegade
open circuit in the wire harness to the headlamp
SENTINEL HEADLAMP DELAY M O D U L E - X J switch.
VEHICLES (6) Measure the voltage between the delay module
SERVICE INFORMATION should indicate battery voltage. If not, repair the
The Headlamp Module delays the de-activation of open circuit in the wire harness to the fuse.
the headlamps for 45 ±15 seconds after the ignition
J LAMPS 8L - 15
DAYTIME RUNNING LIGHTS (CANADA ONLY) REMOVAL- YJ VEHICLES

The daytime running light module is located on the
SERVICE INFORMATION left fender inner panel below the engine air cleaner
The Daytime Running Lights (Headlamps) System housing.
is installed on vehicles manufactured for sale in Can (1) Remove the engine air cleaner housing for ac
ada only. The headlamps are illuminated when the cess to the DRL module.
ignition switch is turned to the ON position. The (2) Disconnect the wire harness connector from the
DRL module receives a vehicle-moving signal from module.
the vehicle speed sensor. This provides a constant (3) Remove the screws that attach the module to
headlamps-on condition as long as the vehicle is the fender inner panel.
moving. The lamps are illuminated at less than 50 (4) Remove the module from the fender inner
percent of normal intensity. panel.
DRL MODULE REPLACEMENT INSTALLATION— YJ VEHICLES
(1) Position the DRL module on the left, fender in
REMOVAL-XJ VEHICLES
The Daytime Running Lights (DRL) module is lo ner panel.
cated on the right fender inner panel adjacent to the (2) Install the attaching screws. Tighten the
dash panel (Fig. 39). screws securely.
(3) Connect the wire harness connector to the mod
ule.
(4) Install the air cleaner housing.
UNDERHOOD L A M P SERVICE INFORMATION

When equipped, the underhood lamp is installed on
the hood right, rear inner panel for all Jeep® vehi
cles. The lamp is illuminated when the hood is
opened. The switch provides automatic ON/OFF func
tions each time the hood is opened and closed.
HOOD WIRE
Fig. 39 Daytime Running Lights (DRL) Module—XJ

Vehicles
module. Fig. 40 Underhood Lamp—XJ Vehicles
(2) Remove the screws that attach the module to
the fender inner panel. UNDERHOOD LAMP BULB REPLACEMENT
(3) Remove the module from the fender inner
panel. REMOVAL-ALL VEHICLES
INSTALLA TION-XJ VEHICLES underhood lamp.
(1) Position the module on the right fender inner (2) Rotate the bulb counter-clockwise and remove
panel. it from the lamp base socket.
(2) Install the attaching screws. Tighten the
screws securely. INSTALLATION-ALL VEHICLES
(3) Connect the wire harness connector to the mod (1) Insert a replacement bulb in the lamp base
ule. socket and rotate it clockwise.
8 L - 16 LAMPS J
WIRE LAMP RETAINER LIQUID

CONNECTOR AND TAB SWITCH
SWITCH ENCLOSURE
SCREW
WIRE HARNESS
HOOD CONNECTOR
\ 1 V
n
L/
CMd>
LAMP
J9223-442 REFLECTOR BULB (105) BASE J928L-1
Fig. 41 Underhood Lamp—YJ Vehicles Fig. 42 Underhood Lamp Components

(2) Connect the wire harness connector to the (3) Remove the screw that attaches the lamp re
lamp. flector and support bracket to the hood inner panel.
(4) Remove the lamp from the hood inner panel.
UNDERHOOD LAMP REPLACEMENT
INSTALLATION-ALL VEHICLES
REMOVAL-ALL VEHICLES (1) Position the underhood lamp on the hood inner
(1) Disconnect the wire harness connector from the panel.
lamp. (2) Install the attaching screw through the lamp
(2) Rotate the bulb counter-clockwise and remove and into the hood panel. Tighten the screw securely.
it from the lamp base socket. (3) Insert a replacement bulb in the lamp base
socket and rotate it clockwise.
(4) Connect the wire harness connector to the
lamp.
J LAMPS 8L - 17
INTERIOR LAMPS
INDEX
page page
Dome Lamp Replacement . . . . . . . . . . . . . . . . . . 18 Illuminated Entry System Service Information . . . 18
Dome/Courtesy Lamp Service Information . . . . . . 17 Illuminated Entry System Trouble Diagnosis . . . . 19
Dome/Courtesy Lamp Trouble Diagnosis . . . . . . . 17 Lighted Vanity Mirror . 17
Hardtop Dome/Cargo Lamp Bulb Replacement—YJ Lighted Vanity Mirror Trouble Diagnosis 17
Vehicles 18 Overhead Console—XJ Vehicles 18
DOME/COURTESY LAMP SERVICE INFORMATION LAMPS INOPERATIVE WITH ONE OR MO

DOORS OPENED
XJ VEHICLES (1) Remove the inoperative switch from the door
Voltage is applied at all times via the dome lamp pillar and connect the switch wire directly to ground.
fuse to each of the interior lamp bulbs. The interior The lamp should light.
lamp bulbs illuminate when they are connected to (2) If not, check for an open circuit in black
body ground via the switch: (ground) wire. Repair as necessary. If lamps still do
• headlamp switch, not light, replace the switch.
• glove box switch,
• door pillar switch, and LIGHTED VANITY MIRROR
• liftgate switch (if the cargo lamp is ON.)
If equipped with Security Alarm Module, refer to SERVICE INFORMATION-XJ VEHICLES
Group 8Q—Vehicle Theft Security System. Both the driver and the front passenger sun visor
can be equipped with a lighted vanity mirror. A
YJ VEHICLES lamp located at each side of the vanity mirror. The
The dome/cargo and courtesy lamps are controlled lamps are switched O N automatically when the mir
via O N / O F F switches. The O N / O F F switches are in ror cover is lifted (Fig. 1).
the lamp ground circuits. Voltage via the dome/cour
tesy lamp fuse is applied directly to the lamp bulbs.
When either door is opened, the door pillar switch
contacts close and provide a direct path to vehicle
body ground.
The cargo/cargo and courtesy lamps can also be
turned on via the interior lamp illumination rheo
stat.
DOME/COURTESY LAMP TROUBLE DIAGNOSIS

ALL LAMPS INOPERATIVE
(1) Rotate the headlamp switch rheostat clockwise.
The lamps should light. If not O K , remove, inspect
and test the dome lamp fuse. Replace if bad.
(2) If the fuse is O K , repair the open circuit in the
wire harness to vehicle body ground. Fig. 1 Lighted Vanity Mirror
ONE LAMP INOPERATIVE Voltage is applied directly to the vanity lamp bulbs
(1) Measure the resistance across the bulb holder via the dome lamp fuse.
terminals. The ohmmeter should indicate zero ohms.
LIGHTED VANITY MIRROR TROUBLE DIAGNOSIS
If not, replace the bulb.
(2) Measure the voltage between the voltage side VANITY LAMPS INOPERATIVE
of the bulb holder and vehicle body ground. The volt (1) Remove, inspect and test the dome lamp fuse.
meter should indicate battery voltage. If not, repair Replace if defective.
the open circuit in the wire harness to the splice. (2) Test the dome lamp operation. If O K , go to the
next step. If not O K , repair the open circuit in the
wire harness from the splice.
8L - 1 8 LAMPS J
(3) Measure the voltage between the pink wire on HARDTOP DOME/CARGO LAMP BULB
the switch connector and vehicle body ground. The REPLACEMENT-YJ VEHICLES
voltmeter should indicate battery voltage. If not OK,
repair the open circuit in the wire harness from the REMOVAL
splice. (1) Remove the dome/cargo lamp lens by squeezing
(4) Connect a jumper wire from the ground side of it at both sides. This will separate the lens retainer
the switch to a good vehicle body ground. Measure tabs from the lamp housing shoulders (Fig. 3).
the resistance to vehicle body ground. The ohmmeter
SQUEEZE
should indicate zero ohms. If not, repair the open cir THE LENS
cuit in the wire harness to vehicle body ground.
DOME LAMP REPLACEMENT

REMOVAL—XJ VEHICLES
(1) Remove the dome lamp lens by squeezing it at
both sides. This will separate the lens retainer tabs
from the lamp housing shoulders.
(2) Pull the lens downward to remove it from the
lamp housing.
(3) Remove the lamp housing retainer clips (Fig.
2).
Fig. 3 Hardtop Dome/Cargo Lamp—YJ Vehicles

(2) Remove the lens from the lamp housing.
(3) Pull the bulb straight out to remove from the
bulb holder.
INSTALLATION
(1) Insert the replacement bulb in the bulb holder.
(2) Position lens at the lamp housing and force it
RETAINING
CLIPS ' into the housing until the retainer tabs are seated.
OVERHEAD CONSOLE-XJ VEHICLES

MAP READING LAMP LENS REMOVAL
(1) Make a straight hook at the end of a large pa
per clip or wire (approximately 1.5-mm/0.06-in diam
eter).
(2) Insert the wire hook into the hole in the lamp
lens and pull downward to detach the lens from the
J918L-15
lamp housing (Fig. 4).
Fig. 2 Dome Lamp Removal/Installation—XJ MAP READING LAMP LENS INSTALLATION
Vehicles (1) Insert the tab at the front of the lamp lens into
(4) Disconnect the wire harness connector. the slot in the lamp housing—shown by arrow 1 in
(5) Remove the lamp housing from the headliner Figure 5.
cavity. (2) Force the rear of the lens upward until it is
seated in the lamp housing—shown by arrow 2 in
INSTALLA TION—XJ VEHICLES Figure 5.
(1) Position the dome lamp housing at the head-
liner cavity. ILLUMINATED ENTRY SYSTEM SERVICE
(2) Connect the wire harness connector. INFORMATION
(3) Install the lamp housing retainer clips (Fig. 2). The Illuminated Entry System that is activated by
(4) Position the lens at the lamp housing and force the system relay (TAN). The relay is located on a
it upward into the housing until the retainer tabs bracket (with 3 relays) behind the instrument panel.
are seated on the lamp housing shoulders. The relay receives input from the door pillar
J LAMPS 8L - 1 !
door. The interior courtesy lamps should immediately

illuminate.
(3) Open driver-side door, enter the vehicle, close
the door and turn the ignition switch to the RUN po
sition. The courtesy lamps should go out. Turn the
ignition switch to the OFF position before exiting ve
hicle.
(4) When exiting the vehicle, the courtesy lamps
should remain illuminated after the door is closed.
(5) From outside the vehicle, open and close the
passenger-side door. The courtesy lamps should illu
minate.
HELA Y BENCH TEST

J908E-8 (1) Attach a "jumper" wire to pin 1. Momentarily
connect pin 1 (battery negative terminal/ground) to
Fig. 4 Map Reading Lamp Lens Removal pin 4. The test bulb should light for 30 ±6 seconds,
then go out. If not, replace the relay.
(2) Momentarily connect pin 1 (battery negative
terminal/ground) to pin 4. The test bulb should light.
Attach a "jumper" wire to pin 5 and momentarily
connect pin 5 to pin 2. The test bulb should go out. If
not, replace the relay.
J908E-9
Fig. 5 Map Reading Lamp Lens Installation

ILLUMINATED
switches, the keyless entry system, and the ignition E N T R Y RELAY
switch (when in the RUN position). When correct in
put is received, the entry module timer immediately
begins the timing-out process. The timing-out process
requires approximately 30 ±6 seconds. — T E S T P O I N T S ( T O U C H MOMENTARILY)
The illuminated entry system also operates
when a door i s opened to exit the vehicle. When PIN 1 GROUND
the door is closed the interior illumination w i l l PIN 2 114-
PIN 3 KEYLESS ENTRY INPUT
continue for the remaining portion of the 30 sec
PIN 4 DOOR J A M B
onds. PSNS K E Y IN R U N I N P U T
Jfl8L-25
ILLUMINATED ENTRY SYSTEM TROUBLE

Fig. 6 Relay Bench Test
DIAGNOSIS
The Illuminated Entry System relay is located on a (3) Momentarily connect pin 1 (battery negative
bracket behind the instrument panel. terminal/ground) to pin 3. The test bulb should light.
(1) Ensure that the ignition switch is in the Off po Next, momentarily connect pin 5 to pin 2 (B + ) and
sition. the test bulb should go out. If not, replace the relay.
(2) Open and immediately close the driver-side
8 L - 20 LAMPS J
ILLUMINATED ENTRY SYSTEM TROUBLE DIAGNOSIS

_ ILLUMINATED ENTRY DIAGNOSIS
V E R I F Y T A N RELAY IS
NO I N S T A L L CORRECT
IN T A N CONNECTOR
RELAY.
BEHIND INSTRUMENT
PANEL.
| YES
R E M O V E RELAY.
T E S T DOME LAMP
NOT REPAIR A S R E Q U I R E D
A N D DOOR J A M B
OK AND RETEST.
S W I T C H FOR N O R M A L
OPERATION.
BENCH T E S T RELAY NOT REPLACE RELAY A N D

FOR P R O P E R O P E R A T I O N . RETEST.
OK
REFER T O B E N C H T E S T .
|oK
CHECK F O R G R O U N D NOT REPAIR O P E N A N D
A T CAVITY 1 O F OK RETEST.
R E L A Y CONNECTOR
OK
CHECK FOR B A T T E R Y NOT REPAIR O P E N A N D

V O L T A G E A T CAVITY OK RETEST.
2 O F R E L A Y CONNECTOR
OK
DISCONNECT B A T T E R Y
A N D CHECK F O R CIRCUIT
CONTINUITY BETWEEN NOT REPAIR A S R E Q U I R E D
CAVITY 3 O F RELAY OK AND RETEST.
CONNECTOR A N D KEYLESS
E N T R Y M O D U L E CONNECTOR
CAVITY C.
OK
CONNECT B A T T E R Y .
CLOSE A N Y DOOR J A M B
REPAIR O P E N A N D
S W I T C H (OPEN A N Y DOOR) NOT
RETEST.
A N D CHECK FOR G R O U N D OK
A T CAVITY 4 O F RELAY
CONNECTOR.
I OK
O P E N A L L DOOR J A M B
S W I T C H E S (CLOSE A L L
DOORS) A N D CHECK FOR NOT REPAIR O P E N A N D
r
BATTERY VOLTAGE A T OK RETEST.

CAVITY 4 O F RELAY
CONNECTOR.
OK
T U R N IGNITION SWITCH REPAIR O P E N FROM
T O R U N A N D CHECK IGNITION S W I T C H
T E S T KEYLESS AND RETEST.
FOR BATTERY VOLTAGE
ENTRY MODULE.
A T CAVITY 5 O F RELAY
CONNECTOR.
• J918L-26
Ju,
* "-"™ r • 1
OK 1
LAMPS 8L - 21
SPECIFICATIONS
XJ EXTERIOR LAMPS XJ INTERIOR LAMPS
EXTERIOR LAMPS BULB TYPE IHTERIOR LAMPS BULB TYPE
Under Panel Courtesy Lamp (2) 168

Backup Lamps (2) 1156 Dome Lamp (1) 561
Dome/Reading Lamp (2) 906
Front P a r k / T u r n Lamps (2) 2Q57NA Dome/Reading Lamp (1) 561
Front Side M a r k e r Lamps (2) 194 Cargo Lamp (1) 561
Lighted Vanity M i r r o r (2) 74
Cherokee Headlights (2) H 6054 Ashtray Lamp (1) 1891
Cigarette Lighter Lamp (1) 53
Rear License Plate Lamp (1) 168 Climate Control Lamp (2) 74
Rocker Switch Lamp (1) 37 (As Required)
S t o p / T a i l Lamps (2) 2057
T r a n s f e r Case Lamp (1) 658
T u r n Signal Lamps (2) 1156 Automatic T r a n s m i s s i o n Floor
Shift Lamp (1) 658
Underhood Lamp (1) 105 Glove Box Lamp (1) 194
Overhead Console (4) 912
J928L-5 J928L-6
YJ EXTERIOR LAMPS
YJ INTERIOR LAMPS
EXTERIOR LAMPS BULB TYPE

INTERIOR LAMPS BULB TYPE
Back-Up Lamps (2) 1156
Courtesy Lamps /
Front P a r k / T u r n Lamps (2) 2057 Under Dash Panel (2) 89

Dome—Cargo
Front Side M a r k e r Lamps (2) 194
(Hardtop Models Only) 212
Headlamps H6054 Ash Tray Lamp 1891
Cigarette Lighter Lamp 53
S t o p / T a i l / T u r n Lamps (2) 1157
Heater Control Lamp 194
Underhood Lamp (1) 105 Rocker Switch Indicator Lamp 74
(Fog Lamps and Rear
Window Defogger)
J928L-11 Automatic Transmission
Indicator Lamp 1445
Glove Box Lamp 194
J908L-35
J REAR WINDOW DEFOGGER 8N - 1
REAR WINDOW DEFOGGER
CONTENTS
page page
GENERAL 1 YJ 4
XJ 4
GENERAL
INDEX
page page
Diagnosis 3 Rear Window Defogger Grid Test 1
Rear Window Defogger Grid Repair 2 Switch Testing 3
Using heating elements bonded to the rear window To stop defogger operation, momentarily push the
glass, the rear defogger will clear condensation, frost switch a second time.
and light snow coverings from the rear window.
The horizontal grid lines and vertical bus bar lines CAUTION: Use care when washing the inside of the
printed and baked on inside surface of rear window rear window to prevent damage to the defogger
glass comprise an electrical circuit. The electrically heating elements. Use a soft cloth and a mild wash
conductive lines are composed of a silver-ceramic ma ing solution. Wiping motions should be parallel to
terial which when baked on glass becomes bonded to the heating elements. Also, keep all objects a safe
the glass and is highly resistant to abrasion. distance from the window to prevent damaging the
The electrical current required to produce the heat heating elements.
in the grid is supplied through a relay and driver op
erated switch. When the switch is momentarily de
REAR WINDOW DEFOGGER GRID TEST
pressed, the relay senses a voltage change. This
It is possible, that a break may exist or occur in an
voltage change causes the relay to change state and
individual grid line resulting in no current flow
complete a circuit to energize the relay. Once the re
through the line. When a grid has an open circuit,
lay energizes, the contacts close connecting the grid
the area of glass normally cleared by that grid re
to battery power.
mains fogged or iced unless, and until it is cleared by
On the XJ, the power circuit to the grid is pro
the adjacent grids.
tected by the 25 amp HTD WDW #18 fuse in the
With the engine running at IDLE, push the rear
fuse box. Power for fuse #18 comes from the Power
window defogger switch to the ON position and re
Distribution Center, fuse F10. Power for the relay is
lease. The pilot lamp in the rocker switch should
protected by the 20 amp Turn #8 fuse located in the
light, indicating defogger operation.
fuse box.
Using a 12 volt DC voltmeter, contact the positive
On the YJ, the grid is protected by a 25 amp fuse,
lead to the feed side vertical bus element on the in
# 6 , located in the fuse box. Power for the relay is
side surface of the glass. Contact the negative lead to
protected by 15 amp fuse, #9 located in the fuse box.
the ground side bus element. Meter should read be
To defog the rear window, momentarily depress the
tween 11 and 13 volts. Connect the negative lead of
rocker switch. A light on the rocker switch will illu
the voltmeter to a good ground; the meter reading
minate indicating that the defogger is operating.
should be constant.
If the ignition switch is ON the first activation of
Keep the negative lead connected to ground. Use
the defog/defrost feature will last for 10 minutes.
the positive lead and carefully contact each grid at
Succeeding activations will last for 5 minutes unless
the approximate centerline of the window.
the ignition switch is turned OFF; then it will recy
cle back to 10 minutes for the first activation.
8N - 2 REAR WINDOW DEFOGGER J
BREAK GRID LINE (3) Attach two strips of masking tape to the inside
surface of the rear window (above and below the
break in the grid) (Fig. 1).
(4) Remove package separator clamp and mix plas
tic conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy.
(5) Apply conductive epoxy through slit in mask
ing tape. Overlap both ends of the break.
(6) For a terminal or pigtail replacement, mask ad
jacent areas so epoxy can be extended onto line and
buss bar. Apply a thin layer of epoxy to area where
MASKING TAPE terminal was fastened and to adjacent line.
(7) Apply a thin layer of conductive epoxy on ter
Fig. 1 Grid Line Repair (Typical) minal and place terminal on desired location. To pre
vent terminal from moving while the epoxy is curing,
A voltage drop of one-half the full amount, approx it must be wedged or clamped.
imately 6 volts, indicates a good grid or closed cir (8) Carefully remove masking tape from grid line.
cuit. (9) Allow epoxy to cure 24 hours at room tempera
A voltage drop of 12 volts at the centerline indi ture or use heat gun with a 260°-371°C (500°-700°F)
cates a break in the grid between the positive volt range for 15 minutes. Hold gun approximately
meter lead and the ground. 254mm (10 inches) from repaired area.
No voltage drop (0 volts) at the centerline indicates (10) After conductive epoxy is properly cured re
a break in the grid between the centerline and the move wedge from terminal and check out operation
voltage source or lead. of rear window defogger. Do not attach connectors
until curing is complete.
The exact location of the break can be pinpointed
by moving positive voltmeter lead to the left or right WARNING: R E P A I R K I T MAY C A U S E S K I N OR E Y E
along grid. An abrupt change in the voltage reading IRRITATION.
will be noticed. The break is at that point in the
grid. CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, HARMFUL IF SWALLOWED. AVOID
REAR WINDOW DEFOGGER GRID REPAIR CONTACT WITH SKIN AND EYES. FOR SKIN,
Locate the broken or open grid. WASH AFFECTED AREAS WITH SOAP AND WA
Use the grid repair kit (available as a service part) TER. DO NOT TAKE INTERNALLY. IF TAKEN IN
by using the following procedure: TERNALLY, INDUCE VOMITING; CALL A
PHYSICIAN IMMEDIATELY. IF IN CONTACT WITH
(1) Mark the location of the broken or open grid on
EYES, FLUSH WITH PLENTY OF WATER. USE
the exterior surface of the glass using a suitable
WITH ADEQUATE VENTILATION. DO NOT USE
marking pencil. NEAR FIRE OR FLAME. CONTENTS CONTAIN 3%
(2) Lightly rub the area to be repaired (inside the FLAMMABLE SOLVENTS.
rear window) using fine steel wool. Clean the area WARNING: KEEP OUT OF REACH OF CHIL
with alcohol. DREN.
J REAR WINDOW DEFOGGER 8N - 3
SWITCH TESTING
SWITCH DIAGRAM
B
DEFOGGER
SWITCH
(Momentary
Contact)
SWITCH TEST
SWITCH POSITION TERMINALS ZSRO OHMS
On/Off B and D Almost z e r o ohms (bulb filament) w i t h switch button depressed
On/Off D and C
A t Rest (Neutral) B and C A l m o s t z e r o ohms (bulb filament)
J928N-1X
DIAGNOSIS • Measure voltage at relay connector terminal 5.
Refer to Group 8W - Wiring Diagrams for a com The meter should read battery voltage. If not, repair
plete circuit diagram. open from (Turn fuse XJ), (fuse #6 YJ).
BATTERY, IGNITION & FUSES • Measure resistance between relay connector termi
• Check fuses #6 and #9 (YJ), HTD/WDW and nal 1 and LH side (driver's side) of defogger grid. The
TURN fuse (XJ). Replace as required. meter should read zero ohms. If not, repair open be
• If the fuses are not blown check the battery side of tween relay connector and LH side of defogger grid.
HTD/WDW fuse (XJ) fuse #6 (YJ) for battery volt • Measure resistance between relay connector termi
age. If battery voltage is not present replace the nal 2 and a clean chassis ground. The meter should
Maxi fuse located in the PDC. read zero ohms. If not, repair open between relay
• Check the ignition side of fuse #9 (YJ), TURN connector and ground.
fuse (XJ) for battery voltage. If battery voltage is not • Connect relay connector and measure voltage at
present check for an open from the ignition switch. terminal 3. The meter should read approximately 5
volts. If not, replace defogger relay.
DEFOGGER SWITCH
Defogger switch connector separated from de INDICATOR LAMP
fogger switch; turn ignition switch to RUN for Refer to switch diagram for resistance tests. If val
voltage tests; turn ignition switch to OFF for re ues do not match, replace defogger switch.
sistance tests
• Measure voltage at defogger switch connector ter DEFOGGER GRID
minal D. The meter should read approximately 5 Turn defogger switch to ON; turn ignition
volts momentarily. If not, repair open from relay. switch to RUN for voltage tests; turn ignition
• Refer to switch diagram for resistance tests. If val switch to OFF for resistance tests
ues do not match, replace defogger switch. • Measure voltage at LH side (driver's side) of De
fogger Grid. The meter should read battery voltage.
DEFOGGER RELAY If not, repair open from defogger relay.
Defogger relay connector separated from de • Measure resistance for RH side of Defogger Grid to
fogger relay; turn ignition switch to RUN for a clean chassis ground. The meter should read zero
voltage tests; turn ignition switch to OFF for re ohms. If not, repair open between RH side of Defog
sistance tests ger Grid and ground.
• Measure voltage at relay connector terminal 4.
The meter should read battery voltage. If not, repair
open to HTD WDW fuse (XJ) fuse #9 (YJ).
8N - 4 REAR WINDOW DEFOGGER J
REAR WINDOW DEFOGGER SWITCH LOWER REAR DEFOGGER RELAY RELAY

INSTRUMENT CENTER
REPLACEMENT PANEL
(1) Remove the instrument panel bezel; see 8E-In-
strument Panel and Components Section for the pro
cedure.
(2) Remove the switch housing panel.
(3) Unplug the switch connector. Slightly depress
the switch mounting tabs and remove the switch.
REAR DEFOGGER RELAY

The rear defogger relay is in the relay center. The
relay center is located on the lower instrument panel
trim cover just right of the steering column.
(1) Remove the RED relay from the relay center
(Fig. 2). o J938N-4
(2) To install the relay, reverse the removal proce

Fig. 2 Rear Defogger Relay Location—XJ
dures.
YJ
REAR WINDOW DEFOGGER SWITCH
REPLACEMENT
(1) Remove 6 shroud screws (Fig. 3)
SWITCH J928N-2
INSTRUMENT * MOUNTING Fig. 4 Defogger Switch—YJ

SHROUD SCREWS
J908K-12 (7) Plug the connector on the switch.
(8) Install the bezel with 3 screws.
Fig. 3 Instrument Shroud Removal/Installation—YJ (9) Install the shroud with 6 screws.
(2) Slide shroud toward the steering wheel.
(3) Remove 3 screws (Fig. 4). REAR DEFOGGER RELAY
(4) Unplug the connector from the defogger switch. The Rear Defogger Relay is in the relay center.
(5) Squeeze the ends of the switch to release the The relay center is located on the lower instrument
panel trim cover just right of the steering column.
plastic retaining fingers and push outward.
(1) Remove the RED relay from the relay center
(6) To install, depress the rear window defogger (Fig. 2).
switch into the bezel until the retaining fingers lock (2) To install the relay, reverse the removal proce
behind the bezel. dures.
J POWER DOOR LOCKS 8P • 1
POWER DOOR L O C K S
CONTENTS
page page
KEYLESS ENTRY 5 POWER LOCKS 1
POWER LOOKS
INDEX
page page
Actuator Motor Stall Test 2 Liftgate Lock Cylinder Replacement 4
Description 1 Solenoid and Latch Assembly Replacement 2
Diagnosing Power Door Locks 1 Switch Replacement 2
General 1
GENERAL NO DOOR LOCKS OPERATE USING DOOR

The door lock actuators, including liftgate, are con LOCK SWITCHES
trolled by two-way switches. To lock the doors, push POWER ACCY circuit breaker installed.
down on either switch. To unlock doors from inside (1) Measure voltage at output side of circuit
the vehicle push upward on either switch. breaker. Meter should read battery voltage. If not,
The power door locks do not lock or unlock the replace circuit breaker.
doors from outside the vehicle. Insert the key into (2) Remove door switch and measure voltage at
the lock cylinder to lock or unlock each individual terminal 1. Meter should read battery voltage. If not,
door. repair open to Dome fuse.
(3) The Power Window relays are in the relay cen
DESCRIPTION ter. The relay center is located on the lower instru
The door locks are operated by reversible motors ment panel trim cover just right of the steering
that receive voltage from the Door Lock and Power column (Fig. 1). Remove both relays.
Seat 30 amp circuit breaker. Voltage is applied to (4) Measure resistance between Lock and Unlock
the LH door lock switch and the RH door lock switch relay terminal 4 (87A) and ground. Meter should
through the dome fuse. With the LH door lock switch read zero ohms. If not, repair open to ground.
in LOCK, voltage is applied through the switch to (5) Measure voltage at terminal 5 (87) of both the
the door lock relay coil. The relay coil is energized Lock and Unlock relays. Meter should read battery
which closes the circuit from the circuit breaker to voltage. If OK, next step. If not, repair open to cir
the lock motor. The motor is grounded by the unlock cuit breaker.
relay. (6) Measure resistance at terminal 2 (85) of both
The RH door lock window switch operates the same the Lock and Unlock relays. Meter should read zero
as the driver's door switch. The voltage and ground ohms. If not, repair open to ground.
paths are reversed to unlock the doors. (7) Hold LH switch in LOCK position. Measure
The power door lock operates with battery power voltage at lock relay terminal 1 (86). Meter should
and, therefore, is independent of the ignition switch. read battery voltage. If OK, next step. If not, repair
A 30 amp circuit breaker mounted in the fuse open to LH switch.
block protects the circuit.
(8) Hold LH switch in UNLOCK position. Measure
DIAGNOSING P O W E R DOOR LOCKS voltage at Unlock relay terminal 1 (86). Meter
If vehicle has Keyless Entry and the door locks op should read battery voltage. If OK, next step. If not,
erate properly using door switches but do not work repair open to LH switch.
with transmitter, refer to Keyless Entry in this
group.
8P - 2 POWER DOOR L O C I S J
(9) Hold LH switch in LOCK position. Measure (2) Disconnect the control linkage and the wire
voltage at Lock relay terminal 3 (30). Meter should harness connector.
read battery voltage. If OK, next step. If not, replace (3) Remove the latch release and control panel as
Lock relay. sembly.
(10) Hold LH switch in UNLOCK position. Mea (4) The switch is retained to the panel with clips
sure voltage at Unlock relay terminal 3 (30). Meter (Fig. 3). Push in on the retainer part of the clip and
should read battery voltage. If OK, check connections pry the clips.
and door motor. If not, replace Unlock relay.
(11) Repeat procedures for RH switch.
INSTRUMENT
PANEL J938P-13
Fig. 1 Door Lock/Unlock Relays

A C T U A T O R MOTOR STALL TEST
To test the actuator motor, connect an ammeter in
series with the motor and operate the door switch. Fig. 3 Power Lock Switch Removal
Replace the actuator motor if current draw exceeds 8
(5) To install the switch, position the switch and
amps at room temperature or if the actuator does not
press in the retainer clips until they snap into posi
complete its travel in less than one second. Refer to
tion.
Removal procedures.
SWITCH REPLACEMENT S O L E N O I D AND L A T C H A S S E M B L Y R E P L A C E M E N T

(1) Remove the interior door latch release assem (1) Remove the interior door latch release assem
bly and control panel retaining screws (Fig. 2). bly and control panel retaining screws (Fig. 2).
(2) Disconnect the control linkage and the wire
harness connector.
(3) Remove the latch release and control panel as
sembly.
(4) Remove the armrest lower retaining screws.
(5) Swing the armrest downward to a vertical po
sition. This is necessary to disconnect the armrest
from the upper retainer clip (Fig. 4).
(6) Pull the armrest straight out from the trim
panel.
(7) Remove the trim panel with a wide flat blade
tool (Fig. 5).
To aid in removal of the trim panel, start at
the bottom of the panel.
(8) Remove the plastic water dam sheet.
(9) Remove the latch retaining screws (Fig. 6).
Fig. 2 Power Window/Lock Control Panel Removal/ (10) Grind out or drill out the lock solenoid rivets
Installation and remove the solenoid with the latch assembly and
remote control rods (Fig. 7).
POWER DOOR LOCKS 8P - 3
J898S-7 J898P-9
Fig. 4 Armrest Retainer Clip Fig. 6 Latch Removal/installation
CUP
ACTUATOR
ROD
RIVETS
Fig. 5 Trim Panel Removal

(11) Place the lock solenoid, latch and remote con
trol rods in the door.
(12) Attach the lock solenoid to the door panel
SOLENOID J898P-10
with pop rivets or nuts and screws.
#
(13) Attach the latch. Tighten the screws to 9 N m Fig. 7 Solenoid Removal/Installation
(7 ft. lbs.) torque.
(14) Install the door trim panel and plastic water
dam sheet.
(15) Using an adhesive/sealant, install the plastic
water dam sheet.
(16) Place the trim panel in the installation posi
tion and press in the nylon retainers.
(17) Install the armrest.
(18) Install the latch release assembly and control
panel.
8P - 4 P O W E R DOOR LOCKS J
L I F T G A T E LOCK C Y L I N D E R R E P L A C E M E N T
(1) Remove two screws at the top outside edges of
the liftgate trim panel.
tool (Fig. 8).
J898F-5
ACTUATOR
Fig. 8 Liftgate Trim Panel Removal LINKAGE CLIP
J898P-12
(3) Disconnect the lock actuator linkage clip (Fig.
9). Fig. 9 Lock Actuator Linkage Clip
(4) Remove three latch retaining screws (Fig. 10).
(5) Remove the latch. LATCH
(6) Drill out two rivets and remove the solenoid. RETAINING
==5CREWS
(7) To install the solenoid, reverse the removal
procedures.
(8) Tighten the latch screws to 9 N*m (7 ft. lbs.)
torque.
J898P-11
Fig. 10 Latch Assembly Removal/Installation

J POWER DOOR LOCKS SP - S
K E Y L 1 S S ENTRY
INDEX
page page
Diagnosing Power Door Locks 6 System Operation 5
Door Lock/Unlock Relay Replacement 8 Transmitter 5
Receiver 5 Transmitter Programming ................... 5
Receiver Service 8 Transmitter Service 8
System Description 5
SYSTEM DESCRIPTION FINGER PADS INDICATOR

The keyless entry system consists of a portable re
mote control transmitter and a receiver mounted be
tween the sun visors. System operation is based on a
coded infrared signal from the transmitter to the re
ceiver. The transmitter is programmed into the re
ceiver providing the correct programming sequence is
met.
When the keyless entry system is activated, the
corresponding relay operates to supply voltage to the
motors. The use of either relay determines the polar
ity of the voltage that is supplied to the door lock
motors.
When the keyless entry system is used, the trans
mitter sends a signal to the keyless entry module. If
the doors are unlocked, the module activates a tran
sistor switch to apply voltage to the lock relay coil.
The coil is energized to close the normally open con
tacts of the lock relay. Battery voltage from the relay
is applied to the door lock motors to lock the doors.
Current flows in the same path to ground as it does J938P-8
when the master door lock switch is used.
When the doors are locked, the keyless entry mod Fig. 1 Keyless Entry Transmitter
ule applies voltage to the unlock relay coil and a unlock relays. The relays complete the circuit to the
similar action takes places to unlock the doors. electric door lock solenoid to either lock or unlock the
doors.
TRANSMITTER
The pocket size, solid state transmitter operates on
SYSTEM OPERATION
2, 3 volt lithium (CR1616) batteries (Fig. 1). The
To activate the system, aim the transmitter diode
transmitter is activated by pressing either the lock
toward the receiver and press the transmitter signal
or unlock button. This closes the internal contacts
that complete the battery circuit. button to lock or unlock the doors as desired.
The battery voltage activates the transmitter diode Effective transmitter range is 4.75 meters (15 ft.)
which in turn generates a coded infrared signal. The with the transmitter positioned no more than 45 de
signal is transmitted as pulses of infrared light. grees from the receiver centerline.
If the red LED on the side of the transmitter does For complete circuit diagrams refer to Group
not light when the transmitter is activated, the bat 8W - Wiring Diagrams.
teries are low.
TRANSMITTER PROGRAMMING
RECEIVER Up to 4 Transmitter Identification Codes (TIC's)
The receiver is in circuit with the electric door lock can be programed into the receiver at any given
system. The coded infrared signal is picked up by the time.
receiver diode and is shaped, amplified and decoded (1) Open the driver's door of the vehicle. Leave it
by an integrated circuit within the receiver. If the open through the programming procedure.
signal code received matches the code in the receiver (2) Move the mechanical door lock lever to the
memory circuit, the receiver triggers the door lock/ LOCK position.
HP - 8 POWER DOOR LOCKS J
(3) Insert the ignition key and turn it to the RUN DIAGNOSING POWER DOOR LOCKS
position.
(4) Turn the ignition to the RUN position. Within NO DOOR LOCKS OPERATE, USING
20 seconds, aim a transmitter at the receiver dome TRANSMITTER
and press the lock button, for at least 5 seconds. (1) Measure resistance at Keyless entry module
Once the receiver accepts the programming code the terminal 10. Meter should read zero ohms. If not, re
driver's door will unlock. pair open to ground.
(5) Once the first transmitter has been pro (2) Measure voltage at Keyless entry module ter
grammed, additional transmitters (up to 4) may be minal 1. Meter should read battery voltage. Battery
programmed into the receiver. Within 20 seconds of
voltage must be at least 9 volts for this system to
the previous transmitter programming, move the me
operate. If not, repair open to Dome fuse.
chanical door lock lever to the Lock position. Aim an
other transmitter at the receiver dome and press the (3) Jumper test leads Keyless entry module termi
LOCK button for at least 5 seconds. The door lock nal 1 to terminal 3. Doors should lock. If OK, replace
will cycle again. module. If not, repair open from terminal 3 to Lock
(6) To lock the programmed codes into the re relay terminal 1.
ceiver, the ignition must be turned off and back on (4) Jumper test leads Keyless entry module termi
within 20 seconds after programming the last trans nal 1 to terminal 4. Door should unlock. If OK, re
mitter's code. At that time, all previous codes are place module. If not, repair open from terminal 4 to
erased from the module. Unlock relay terminal 1.
1 2 V O L T S m ALL T I M E S
1 2 V O L T S A T ALL T I M E S
DOME FUSE | FUSE
10 A M P J PANEL 20 P O W E R ACCY I F U S E
nr_j AMP
FUSE #13
CIRCUIT
BREAKER
! PANEL
!
M A S T E R DOOR L O C K / P O W E R
A__JMNDQW M!IQ^3i?EMBlY
KEYLESS ENTRY
r SWITCH i f SWITCH 2 WINDOW
MODULE
^ SWITCHES
j • LOCK UNlOCKf LOCK
OLOCK
SWITCH 3 SWITCH 4 *
1
RH
DOOR
LOCK/
SWITCH
ASSEMBLY
LIFTGATE LH REAR LH FRONT RH REAR RH FRONT

LOCK DOOR LOCK DOOR LOCK DOOR LOCK DOOR LOCK
MOTOR MOTOR MOTOR MOTOR MOTOR
(4 D R ONLY) (4 D R ONLY) J938P-14
POWER DOOR LOCKS

8P - 8 P O W E R DOOR LOCKS
J
T R A N S M I T T E R SERVICE
If the receiver malfunctions, only the receiver will
have to be replaced. The new receiver will have to be
reprogrammed. If a transmitter is lost, replace the
transmitter and reprogram the receiver.
Batteries may not be supplied with some re
placement transmitters. Be sure to check a re
placement transmitter before attempting to
activate the system.
TRANSMITTER BATTERY REPLACEMENT

(1) Separate transmitter at middle seam (Fig. 2).
Fig. 4 Battery Installation

RECEIVER SERVICE
(1) Remove 2 screws attaching receiver housing to
headlining (Fig. 5).
Fig. 2 Separate Transmitter Halves

(2) Remove and discard old batteries (Figs. 3, 4).
HOUSING
J938P-15
Fig. 5 Remove/Install Keyless Entry Housing

(2) Pull housing toward rear of vehicle to disen
gage clip.
(3) Disconnect receiver harness connector.
Fig. 3 Battery Removal (4) Remove circuit board from housing.
(5) Reverse the removal procedures to install the
(3) Install the new CR 1616 batteries. Re sure the
batteries are installed according to polarity as shown receiver.
on the transmitter battery receptacles.
DOOR LOCK/UNLOCK R E L A Y R E P L A C E M E N T
(4) Assemble the transmitter and verify the correct
The Power Window relays are in the relay center.
battery installation. The voltage indicator light will
The relay center is located on the lower instrument
glow when the batteries are properly installed.
panel trim cover just right of the steering column
(Fig. 6). Remove both relays.
J POWER DOOR LOCKS SP - S
(1) Remove the appropriate relay from the relay

center.
(2) To install the new relay(s) reverse the removal
procedure.
INSTRUMENT
PANEL J938P-13
Fig. 6 Door Lock/Unlock Relays

J POWER SEATS 8R - 1
POWER SEATS
CONTENTS
page page
DIAGNOSIS ... 1 POWER S E A T MOTOR REPLACEMENT 2

GENERAL ... 1 SWITCH TESTING 2
GENERAL through pin S4 and the contacts of the back switch to

The power seat can be adjusted in 6 different direc pin 2 and to ground. The motor runs to drive the seat
tions (Fig. 1). The control switch is on the lower out forward until the switch is released.
board side of the seat. With the switch in the REAR position, pin S4 re
The front lever on the switch raises or lowers (tilts) ceives battery voltage and pin S3 is grounded. This
the front of the seat; the center lever raises or lowers reversed polarity causes the motor to run in the op
the complete seat by moving the switch up or down. posite direction and drive the seat backward.
It also moves it forward or rearward by moving the The front motor works in a similar way when the
switch forward or rearward. The rear lever raises or front height switch is operated.
lowers (tilts) the back of the seat. To raise the entire seat, the center position seat
switch is held in the UP position. This applies bat
tery voltage to both pins SI and S5 and the front and
rear motors. Pins S2 and S6 are grounded through
the down switches and the lower switch. Both motors
run to drive the entire seat up. A similar action oc
curs to move the entire seat down.
Each motor contains a self-resetting circuit breaker
to protect it from overload. Consecutive or frequent
resetting must not be allowed to continue. Make nec
essary repairs.
DIAGNOSIS
Refer to Group 8W-Wiring Diagrams for a complete
FRONT
circuit diagram.
Before any testing is attempted the battery should
be fully charged and all connections and pins cleaned
and tightened to insure proper continuity and
1. SEAT UP AND DOWN
2. SEAT FORWARD AND REARWARD grounds.
3. SEAT TILT (FRONT U P A N D D O W N ) With the dome light on, apply switch in direction
4. SEAT TILT (REAR U P A N D D O W N )
of the failure. If the dome light dims, the seat may
J918R-1 be jamming. Check for binding. If the dome light
does not dim, then proceed with the following electri
Fig. 1 Power Seat Switch cal tests.
There are 3 reversible motors that operate the
SEAT MOTOR ASSEMBLY
power seat. The front and rear of the seat are oper
• Position Seat Switch to move all 3 Seat Motors.
ated by different motors. They can be raised or low
The seat should move in all directions. If not, go to
ered independently of each other. Moving the center
position seat switch to either the UP or DOWN posi No Seat Motors Operate. If one or more motors oper
tion, runs both the front and rear motors at the same ate, refer to switch testing.
time. Test Seat Switch. If ok, replace defective motor.
The forward-rearward motor is operated by the NO SEAT MOTORS OPERATE
center position seat switch. When the switch is held PWR ACCY breaker installed.
in the FORWARD position, battery voltage is applied
• Probe PWR ACCY circuit breaker, on fuse panel.
through the switch contacts to pin S3 and the for
If battery voltage is present, replace circuit breaker.
ward-rearward motor. The motor is grounded
• Remove switch mounting screws and measure volt POWER
age at Red wire at switch. Meter should read battery MOTOR SEAT MOTOR
ASSEMBLY
voltage. If not, repair open to power. ASSEMBLY
ATTACHING
• Measure resistance at black wire at switch. Meter SCREWS
should read zero ohms. If ok, replace switch. If not,
repair open to ground.
SWITCH TESTING
POWER SEAT MOTOR REPLACEMENT

(1) Disconnect power seat wire harness at motor.
(2) Remove bolts attaching seat frame to floor pan
and remove seat.
(3) Disconnect motor ground wire. DRIVE
CABLES
CAUTION: Take care to avoid excessive bending of
the 3 drive cables when removing/installing the mo
tor assembly. J918R-3
(4) Remove screws attaching motor assembly to Fig. 3 Power Seat Motor Assembly
seat frame and remove motor assembly and mount
ing spacers (Fig. 3).
(5) To install power seat motor, reverse the re DRIVER SIDE
moval procedures.
FRONT
I
FRONT
W / M r II((
CENTER / REAR
— O F
VEHICLE SECTION SECTION / SECTION
BLACK WHITE
S W I T C H DIAGRAM
SEAT
YELLOW \
Z TAN ORANGE LT. B L U E
J
FRONT SWITCH LT. G R E E N J898R-5
REAR 1 FRONT REAR"t 1 DOWN
fwd J Tback UP \ I UP DOWN" :
n rgi LOWER \
j iflfit 1 j
J898R-3
Fig. 2 Switch Diagram

J POWER SEATS 8R - 3
SWITCH T E S T
SWITCHES 1, 2 A N D 3 (GROUNDS)
SWITCH P O S I T I O N TERMINALS ZERO OHMS
2 AND: S I , $2, S3, S 4 , $5 A N D S 6 YES

OFF (NORMAL)
1 AND 2 NO
SWITCH T E S T
SWITCH 1
UP (FRONT) 1 AND S5 YES
D O W N (FRONT) 1 AND S6 YES
SWITCH T E S T
SWITCH 2
1 AND SI YES
U P (RAISE)
1 AND S5 YES
1 AND S2 YES
D O W N (LOWER)
1 AND S6 YES
FORWARD (FWD) 1 AND S3 YES
B A C K W A R D (BACK) t AND S4 YES
SWITCH T E S T
SWITCH 3
U P (REAR) 1 AND SI YES
D O W N (REAR) t AND S2 YES

POWER WINDOWS 8S - 1
J
POWER WINDOWS
CONTENTS
page page
DESCRIPTION 1 SWITCH TESTING 4

DIAGNOSIS 1 WINDOW REGULATOR REPLACEMENT 7
DESCRIPTION NO WINDOWS OPERATE

All XJ vehicles, equipped with power windows, • Measure voltage at power window feed connector
have a cable driven window regulator system. A per at fuse panel. Meter should read battery voltage. If
manent magnet motor moves each power window. not, replace 60 amp fuse in Power Distribution Cen
Each motor raises or lowers the glass when voltage ter.
is supplied to the motor. The direction the motor • Turn key to OFF and measure resistance from side
turns depends on the polarity of the supply voltage. of cigar lighter socket to ground. Meter should read
The control switches control the supply voltage polar zero ohms. If not, repair open to ground.
ity. • Remove Master Door Lock/Power Window Switch
With the ignition switch in the RUN position volt assembly mounting screws. Measure resistance at
age from the 60 amp fuse in the Power Distribution BLK wire (terminal DX) at LH switch. Meter should
Center is applied through the power window circuit read zero ohms. If not, repair open to ground splice of
breaker. Power then goes to the master switch termi LP. harness
nal BY and to the passenger's window switches. • Turn key to ON and measure voltage at terminal
When the driver's window switch is moved UP, the BY at LH switch. Meter should read battery voltage.
contacts close a current path to: If not, repair open circuit to breaker.
• terminal DV
• Operate Window switch. If the windows move up
• the Left Hand front window motor
and down go to Switch Testing.
• terminal CV
• the DOWN contact of the Left Hand front window • Perform Drivers Door Switch test. If switch passes
to ground. test, replace defective motors.
The motor then moves the glass up.
ONE WINDOW OPERATES
Current flows in a similar way when the UP con
tact in one of the passenger's window switches is Remove door panel of inoperative window,
closed. Current flow through the passenger's window probe harness side of unplugged motor connec
motors must go through the driver's and the passen tor,
ger's window switches before it reaches ground. • Measure voltage at terminal A of connector, hold
Each motor is protected by a built-in circuit ing switch in the DOWN position. Meter should read
breaker. If a window switch is held on too long with battery voltage. If not, repair open back to Master
the window obstructed or after the window is fully Switch. If additional switch is in circuit (not LH mo
up or down, the circuit breaker opens the circuit. The tor), refer to Switch Testing.
circuit breaker resets automatically as it cools. Do • Measure resistance at terminal B of connector,
not allow frequent or consecutive resetting of the cir holding switch in the DOWN position. Meter should
cuit breaker to continue. read zero ohms. Caution, maintain DOWN position
while meter lead is attached. If not, repair open back
DIAGNOSIS (Figs. 1 and 2) to Master Switch. If additional switch is in circuit
For information concerning wiring or connectors, (not LH motor), refer to Switch Testing. If both tests
refer to Group 8W - Wiring Diagrams. are OK, replace regulator.
8S - 2 POWER WINDOWS J
60 , FUSE POWER
AMP DISTRIBUTION
CENTER
IGNITION
12 OR 12 OR 13 SWITCH
RUN
F U S E
30 4 POWER WINDOW J A N E L
• A M P j ^ CIRCUIT BREAKER J P
12 T N M A S T E R DOOR L O C K / P O W E R
BY W I N D O W SWITCH ASSEMBLY
L H REAR LOCKOUT SWITCH R H REAR IH F R O N T n r ) W K 1 u p
s i — P
» y IT" 1 #
UNLOCK f - * LOCK
CV DV CY DY AY EY FY EV FV DX
14 Y L 14 BK
14 LB 14 W T
A A B 14 BL 14 R D 14 Y L 14 G R 14 Y L 14 G R 14 YL 14 V T
WT BK BK WT WT
14 BR
WT
LH FRONT
WINDOW EZL EX FX RH FRONT
MOTOR
• DOOR
L H REAR J
i i n WINDOW DOWN UP •down}"™
y p LOCK/
DOWN £ WINDOW
SWITCH I
i • . t — J SWITCHES
Bl EYRHREAR EYf py
14 L^T YL 14 LB 14 Y L WINDOW 14 LB 14 V T
A&--
SWITCH A£- - * B
vB
RH FRONT
L H REAR R H REAR
WINDOW
WINDOW WINDOW
MOTOR
MOTOR MOTOR
J918S-1
Fig. 1 Power Windows 4-Door—XJ

POWER WINDOWS SS
POWER
DISTRIBUTION
CENTER
IGNITION
SWITCH
14 OR 12 O R
POWER W I N D O W
30 \ CIRCUIT BREAKER
AMP J P W R ACCY j F U S E P A N E L
-———————J
14 VT M A S T E R DOOR LOCK/POWER
BY
W I N D O W SWITCH ASSEMBLY
L H DOOR LOCKOUT SWITCH R H DOOR
UNLOCK A LOCK
V 1 DOWN U P
DOOR LOCKS
-Mil- — *
A T " ~ ~
T
DVY14 YL
14 OR
DX
14 B K
RH
DOOR/LOCK
WINDOW
SWITCH
RH
WINDOW
MOTOR
WINDOW
MOTOR
J918S-2
Fig. 2 Power Windows 2-Door—XJ

SWITCH TESTING
DRIVERS DOOR POWER WINDOW SWITCH—2-DOOR
A B CD
UNLOCK LF
LOCK DR
UNLOCK RF
LOCK W D W ®
SWITCH DIAGRAM MASTER DOOR LOCK/POWER

BW WINDOW SWITCH ASSEMBLY"
S
SWITCH 1 'J SWITCH 2 LOCKOUT SWITCH
DOWN UP
A DOOR LOCKS
SWITCH TEST
Switch Grounds
DX and: AV, BV, CV

Yes
DV, CY, DY
O f f (Normal) B W and DX No
BY and DX No
SWITCH TEST
L H Door
Up BY and D V Yes
Down BY and CV Yes
SWITCH TEST
RH Poor

Up BY and D Y Yes
Down BY and CY Yes
SWITCH TEST
Lockout Switch
U p (Unlock) AY and BY Yes

Down (Lock) AY and BY No
J938S-9
J POWER WINDOWS 8S - 5
DRIVERS DOOR POWER WINDOW SWITCH—4'DOOR
SWITCH TEST
Switch Grounds
DX and: AV, BV, CV, DV,

Yes
CY, DY, EY, FY, EV, FV
O f f (Normal) B W a n d DX No
BY and DX No
SWITCH TEST
LH Front
Up BY and D V Yes
Down BY and CV Yes
SWITCH TEST
LHRear
Up BY and D Y Yes
Down BY and CY Yes
SWITCH TEST
Lockout Switch
U p (Unlock) AY and BY Yes

Down (Lock) AY and BY No
SWITCH TEST
RH Rear
Up BY and F Y Yes
Down BY and E Y Yes
SWITCH TEST
RH Front
Up BY and FV Yes
Down BY and E V Yes
J928S-3
88 - 6 POWER WINDOWS
PASSENGER DOOR WINDOW SWITCH
SWITCH MARRAM
EW
E W FW
FW FU EZ EX
DOOR LOCK/
WINDOW
SWITCH
-i DOWN ASSEMBLY
"TxxJlT WINDOW
LOCK
UNLOCK UP SWITCH
SWITCH
EV EY
SWITCH TEST
W i n d o w Switch
EY and E Z Yes
O f f (Normal) FY and FX Yes
All Others No
EY and E Z Yes
Up EX and FY Yes
All Others No
EX and EY Yes
Down FX and FY Yes
All Others No
J898S-1
J POWER WINDOWS 8S - 7
WINDOW REGULATOR REPLACEMENT To aid in removal of the trim panel, start at

REMOVAL (7) Remove the trim panel with a wide flat blade
(1) Remove the interior door latch release assem tool (Fig. 5).
bly and control panel retaining screws (Fig. 3).
Fig. 5 Trim Panel Removal

Fig. 3 Power Window Control Panel Removal/
(8) Remove the plastic water dam sheet.
Installation
(9) Grind the heads off 2 rivets holding reinforce
(2) Disconnect the control linkage and the wire ment to door (Fig. 7). Knock rivets out with a ham
harness connector. mer and punch.
(3) Remove the latch release and control panel as (10) Remove 2 screws holding bottom of regulator
sembly. to door.
(4) Remove the armrest lower retaining screws. (11) Remove door glass attaching Torx head screw
(5) Swing the armrest downward to a vertical po (Fig. 6).
sition. This is necessary to disconnect the armrest
from the upper retainer clip (Fig. 4).
J898S-7 Fig. 6 Remove/Install Glass Attaching Screw

(12) Pull glass to the full up position and tape
Fig. 4 Armrest Retainer Clip
glass to door.
(6) Pull the armrest straight out from the trim (13) Disconnect wire harness connector from the
panel. window regulator.
(14) Remove remaining window regulator attach

ing screws (Fig. 7).
(15) Remove window regulator.
INSTALLATION
(1) Place regulator inside door.
(2) Attach regulator to door using screws or the
hardware kit supplied with a new regulator. DO
NOT install the 2 screws that hold the bottom of the
regulator.
(3) Connect wire harness connector to regulator.
(4) Attach door glass with Torx head screw (Fig.
6). Tighten door glass screw to 3.3 N*m (30 in. lbs.)
torque.
(5) Install the last 2 screws.
(6) Using 3M 08044 or 3M 08041 adhesive/sealant,
install plastic water dam sheet.
(7) Place trim panel in the installation position
and press in nylon retainers.
(8) Install the armrest.
(9) Install latch release assembly and control
panel. Fig. 7 Window Regulator Removal
J POWER MIRRORS 8T- 1
POWER MIRRORS
CONTENTS
page page
DIAGNOSIS 1 POWER MIRROR SWITCH REPLACEMENT ... 4

GENERAL 1 POWER MIRROR SWITCH TESTING . . . . . . . . . 2
POWER MIRROR REPLACEMENT 4
GENERAL same motor receives voltage. Now the polarity is re

For information concerning wiring or connectors, versed, with pin E grounded. The motor runs in the
refer to Group 8W - Wiring Diagrams. opposite direction.
The mirror control switch contains two separate The RH left-right motor operates in a similar man
switches, the operating switch and the selector ner when the control switch is moved to the L or R
switch. positions.
Each mirror has two reversible motors: one to ad The LH mirror works the same way as the RH mir
just the mirror view up and down, the other to adjust ror when mirror select switch is moved to LH posi
the mirror view right and left. The driver operates tion and control switch is operated.
three switches that control the polarity of the voltage
to the motors. The mirror select switch directs these DIAGNOSIS
control voltages to either the RH or LH mirror. For information concerning wiring or connectors,
The mirror select switch must be set to L or R to refer to Group 8W - Wiring Diagrams.
direct current flow. If the mirror select switch is set • Open Door. Dome lamps should light. If not, check
on R and the up-down switch is moved to the UP po dome fuse.
sition, the voltage path is: Remove switch, unplug switch connector
• through the U contact of switch 1 • Measure resistance at mirror switch connector pin
• to pin E F. Meter should read zero ohms, If not, repair open to
• to the up-down motor in the RH mirror. ground.
The ground path is: • Measure voltage at mirror switch connector pin G.
• through pin D Meter should read battery voltage. If not, repair open
• through the mirror select switch contacts to Dome fuse.
• to the U contacts of switch 3 and switch 2 Install a jumper lead from pin E to pin F.
• to pin F • Connect a jumper lead from pin G to: pin A; pin B;
• to ground. pin C and then pin D. If the mirror moves, replace
The RH motor runs and tilts the mirror up. switch. If not, repair open to motor and/or replace
If the switch is pushed to the DOWN position, the motor.
8T - 2 POWER MIRRORS
J
POWER MIRROR SWITCH TESTING
J928T-1
J POWER MIRRORS 8T- 3
SWITCH TEST WITH SWITCH IN LEFT (L) POSITION
AandG Yes
Push Down (D) EandF Yes
All Others No
A and F Yes
Push Up (U) E and G Yes
All Others No
Off (Normal) All Others No
BandG Yes
Push Left (L) E and F Yes
All Others No
Band F Yes
Push Right (R) E and G Yes
All Others No
J918T-1
SWITCH TEST WITH SWITCH IN RIGHT (R) POSITION
DandG Yes
Push Down (D) EandF Yes
All Others No
Dand F Yes
Push Up (U) E andG Yes
All Others No
Off (Normal) All Others No
CandG Yes
Push Left (L) EandF Yes
All Others No
CandF Yes
Push Right (R) EandG Yes
All Others No
J918T-2
8T - 4 POWER MIRRORS J
POWER MIRROR SWITCH REPLACEMENT (5) Swing armrest downward to a vertical position.
(1) Using a wide flat blade tool, pry the switch This is necessary to disconnect the armrest from the
housing away from the center console (Fig. 1). upper retainer clip (Fig. 3).
Fig. 1 Power Mirror Switch Removal/Installation—XJ

(2) Disconnect switch connector and remove
switch.
(3) To install a new switch, reverse the removal
procedure. JW8S-7
POWER MIRROR REPLACEMENT . Fig. 3 Armrest Retainer Clip

(1) Remove interior door latch release assembly (6) Pull the armrest straight out from the trim
and control panel retaining screws (Fig. 2). panel.
tool (Fig. 4).
Fig. 2 Power Window Control Panel Removal/

Installation
(2) Disconnect control linkage and wire harness
connector.
(3) Remove latch release and control panel assem Fig. 4 Trim Panel Removal
bly.
(4) Remove armrest lower retaining screws.
J POWER MIRRORS 8T * 5
(8) Remove screw holding mirror trim cover (Fig. (10) Pull harness up through door.
5). (11) Remove 3 screws holding mirror to door (Fig.
6).
Fig. 5 Power Mirror Trim Cover—XJ

(9) Disconnect power mirror wire harness at con Fig. 6 Power Mirror Removal/Installation—XJ
nector in door. (12) To install a power mirror, reverse the removal
procedure.
J —^ ^ C H I M E / B U Z Z E R W A R N I N G SYSTEMS 8U- 1
CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
GENERAL 1 OPERATION/DIAGNOSIS .................. 1

IGNITION KEY WARNING SWITCH REPLACEiENT . 4
GENERAL
The buzzer or optional chime module is mounted on • The key is in the ignition and the driver's door is
the left side of the fuse block (above and to the left of open (On some vehicles, the buzzer will not sound if
the brake/clutch pedal). The buzzer or chime sounds the ignition switch is in the RUN position).
an audible warning tone in any of the following con • The ignition is switched ON and the driver's seat
ditions: belt is not buckled. Buzzer will quit after 4 to 8 sec
• Vehicle lights are ON when the ignition has been onds. Besides the buzzer, a seat belt light indicator
switched OFF and the key is removed and then the
turns on as a reminder to fasten seat belt.
driver's door is opened (except YJ).
OPERATION/DIAGNOSIS
OPERATION On some vehicles the chime/buzzer will not
Battery voltage for module operation is supplied to sound if the door is open and the key is in the
two pins. Voltage is always present at pin 7. Pin 1 RUN position.
receives voltage when the ignition switch is in the
RUN or START position. LIGHTS ON (EXCEPT YJ)
To sound the lights on warning, the following must
SEAT BELT WARNING occur:
The seat belt warning system uses both visual and • the headlamp switch must be closed
audible signals. These consist of a buzzer that is part • the driver's door jamb switch must be closed.
of a combined seat belt and key warning buzzer and These conditions ground pin 6 of the module. These
a red light on the instrument panel. switches are closed when the headlamp switch is on
The system will always illuminate the seat belt and the driver's door is open.
warning lamp for four to eight seconds when the ig
DIAGNOSIS
nition switch is turned to the ON position. Also, only
If the buzzer/chime unit does not operate as de
if the driver does not fasten his seat belt, the buzzer
scribed, check the two fuses for pins 1 and 7 (Figs. 1
will sound during the same time interval. Passenger and 2) and replace as required. If the fuses are not
belts are not connected to the system. defective, perform the following tests to determine if
A timed buzzer-relay is used to operate the system the problem is in the module or in the wiring. Using
for the time period. It has a time delay mechanism a flat head screwdriver, release the locking plastic
and buzzer assembly. Only the driver's seat belt clip while carefully pulling out the module. Plug in a
buckle has a switch that is connected to the system. known good module and check its operation. If the
problem is not corrected by replacing the module, re
KEY IN IGNITION move the module and continue as follows:
To sound the key in ignition alarm, the following
must occur: VOLTAGE TESTS
• the ignition key warning switch must be closed Ignition in run position, measure between the
• the driver's door jamb switch must be closed. following pins and vehicle ground.
These conditions ground pin 6 of the module. These • Measure voltage at buzzer/chime module connector
switches are closed when the key is in the ignition pin 1. Meter should read battery voltage. If not, re
and the driver's door is open. pair open to ignition switch.
Turn ignition off and remove the key from the ig
nition.
8U - 2 CHIME/BUZZER WARNING SYSTEMS
TERMINAL 7 TERMINAL 6 Measure between the following pins and vehi

T O DOOR S W I T C H
TOB+ cle ground.
KEY IN S W I T C H A N D
HEADLAMP O N • Buzzer/chime module connector pin 2. Meter
S W I T C H (EXCEPT YJ) should read almost zero ohms (bulb filament). If not,
replace seat belt indicator bulb.
• Buzzer/chime module connector pin 3. Meter
should read zero ohms. If not, repair open to ground.
• Buzzer/chime module connector pin 4. Drivers seat
belt not buckled. Meter should read zero ohms. If not,
repair open to ground (or buckle switch may be de
fective). Meter should read open circuit if drivers
seat belt is buckled. If not, repair short to ground (or
buckle switch may be defective).
• Buzzer/chime module connector pin 6. Open driv
TERMINAL 4
T O SEAT BELT
TERMINAL 1 er's door, key in ignition (in OFF position). Meter
TO IGNITION should read zero ohms. If not, repair open to ground.
BUCKLE SWITCH
SWITCH
• Buzzer/chime module connector pin 6. Remove key
TERMINAL 2 from ignition. Open driver's door, headlamp switch
TERMINAL 3 TO SEAT BELT
TO GROUND WARNING LIGHT
on (except YJ), meter should read zero ohms. If not,
J928U-2
repair open to ground.
Fig. 1 Buzzer Module Connector Terminal
Identification—Pin Side
L I G H T S - O N / K E Y - I N -IGN ITION
WARNING
BATTERY ( + )
SEAT BELT
SEAT BELT GROUND SWITCH
IGNITION
WARNING LIGHT J928U-9
Fig. 2 Buzzer Module Terminal Identification

• Measure voltage at buzzer/chime module connector
pin 7. Meter should read battery voltage. If not, re
pair open to fuse.
RESISTANCE TESTS
CAUTION: Before using an ohmmeter, turn ignition

switch O F F and disconnect negative cable from bat
tery to avoid damaging the meter.
J CHIME/BUZZER WARNING S Y S T E M S 8U - 3
I—1 DOORSW I—I DOORSW

A
' (SHOWN DOOR CLOSED) * • 7 (SHOWN DOOR CLOSED)
UGHTS SW
5
KEY S W (SHOWN LIGHTS OFF) KEYSW* 1
(SHOWN KEY OUT) (SHOWN KEY OUT) / — „
B+
Park/Toll #15
5 6 7 8
•• •• ••3 •
•
1 2 4
Gauges
* # #17
17-JSEAT
• " " H S r
IGN SW
(SHOWN IGN OFF)
LAMP
BELT
I SEAT BELT SW
(SHOWN
BUCKLED) IGNSW
(SHOWN IGN OFF)
LAMPT
"
i '±r BUCKLED)
Duuueui
PIN VIEW (SAME AS REAR SIDE [WIRE SIDE) PIN VIEW (SAME AS REAR SIDE [WIRE SIDE]
CONNECTOR VIEW) CONNECTOR VIEW)
X - Do Not Care X - Do Not Care
SEAT DRIVER'S HEAD SEAT DRIVER'S
FUNCTION DESCRIPTION IGN. BELT DOOR KEY LAMPS FUNCTION DESCRIPTION IGN. BELT DOOR KEY
4 to 8 Second Ôn Not 4 to 8 Second ^•On Not
Tone and Bckid X X X Tone and Bckid X X
Seat Seat Lamp Output OffA
Lamp Output OffA Belt
Belt
Reminder 4 to 8 Second ^•On Reminder 4 to 8 Second ^•On
LampÔutput Bckid X X X LamgOutput Bckid X X
Off* OP
Key and Continuous, In X Key Continuous, In
Head Lamp Steady X X Open Reminder* Steady X X Open
Reminder* Tone X On Tone X
*On some vehicles, the key switch opens when the ignition is *On some vehicles, the key switch opens when the ignition is
switched on. switched on.
J928U-10 J928U-1
Fig. 3 Buzzer Module Schematic—XJ Fig. 4 Buzzer Module Schematic—YJ

8U - 4 CHIME/BUZZER W A R N I N i SYSTEMS J
IGNITION KEY WARNING S W I T C H REPLACEMENT

(2) Remove horn button with a push and turn mo COMPRESSOR
tion.
STEERING HORN COLUMN
WHEEL CONTACT
INSULATOR
HORN P A D
FLEX-PLATE
RECEIVER J8919-120
BUSHING
J9219-54
knob.
(4) Turn key to lock position and remove steering TURN/HAZARD TURN/HAZARD
DIMMER SWITCH ATTACHING SCREW
wheel nut and washer. SWITCH
SWITCH
(5) Scribe an alignment mark on steering wheel in ACTUATOR
ARM
line with mark already existing on end of steering SCREW
column.
(6) Remove vibration damper from steering column
hub, if equipped.
(7) Remove steering wheel using a steering wheel
puller. DO NOT hammer on puller or end of steering
shaft.
WARNING: T O R E M O V E T H E S T E E R I N G S H A F T
P L A T E M U S T B E C O M P R E S S E D . DO N O T A T
T E M P T T O REMOVE T H E L O C K P L A T E W I T H O U T
C O M P R E S S O R T O O L C4156 A S T H E L O C K P L A T E
I S U N D E R HEAVY S P R I N G T E N S I O N

SCREWS J938K-18
(10) Remove compressor tool. Arm Screws
bearing preload spring. (15) Remove turn/hazard switch attaching screws
(12) Remove horn button components from cancel (Fig. 3).
(16) Unplug wiper switch connector.
ing cam.
(17) Push turn/hazard connector up and out of
4 CHIME/BUZZER WARNING SYSTEMS 8U - 5
steering column connector (Fig. 4). (21) Remove key warning buzzer switch and re
taining clip with a paper clip. Insert paper clip below
retainer so that retainer is flattened (Fig. 5).
Do not attempt to remove buzzer switch and
clip separately. The clip could fall into the col
umn jacket.

Connectors
(19) Pull turn/hazard switch out of the column far Fig. 5 Buzzer Switch Removal
enough to allow access to remaining screws.
(20) Insert ignition key in the lock cylinder and (22) Reverse the removal procedures to assemble
steering column.
turn key to ON position.
(23) Install steering wheel. Tighten steering wheel
nut to 34 N»m (25 ft. lbs.) torque.
J WIRING DIAGRAMS 8W - 1
WIRING DIAGRAMS
CONTENTS
page page
FUSE CHARTS AND RELAY BANKS 8 WIRING DIAGRAMS XJ 131
GENERAL INFORMATION 1 XJ SPLICE LOCATIONS 49
WIRING AND COMPONENT IDENTIFICATION . 1 3 YJ SPLICE LOCATIONS 43
WIRING DIAGRAMS YJ 57
GENERAL INFORMATION
INDEX
page page
Circuit Identification 2 Secondary Ignition Wiring 1
Component Identification 3 Splice Locations 3
Connectors 3 Symbols, Fuses and Abbreviations . 6
Fusible Links 3 Troubleshooting Wiring Problems 3
Harness Repair 3 Wire Code Identification 2
Locating A System 2 Wiring Diagram Sheets and Indexes 1
The wiring diagrams contain the latest information

at the time of publication.
Throughout this group references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
SECONDARY IGNITION WIRING

Secondary ignition wiring is shown in Figures 1
and 2. For additional information on ignition systems
or distributor operation refer to Group 8D Ignition
Systems.
Fig. 2 Secondary Ignition Wiring 4.0L

WIRING DIAGRAM SHEETS AND INDEXES
The diagrams are organized to show the basic ve
hicle and all of its options. Add-on or non-factory op
tions are not covered. The diagram pages are
identified by a sheet number which is located at the
lower right or left hand corner of each sheet. Page
numbers at the top of each page do not apply to
diagram sheets.
Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in
ternal circuity, connectors, splices, and pin identifica
tion for controllers and modules.
Fig. 1 Secondary Ignition Wiring 2.5L
8W - 2 WIRING DIAGRAMS
18 LB/YL*
STANDARD STANDARD
COLOR COLOR COLOR
TRACER COLOR TRACER
CODE COME
COLOR CODE
BL BLUE WT OR ORANGE BK
COLOR O F WIRE
(Light Blue with Yellow Tracer) BK BLACK WT PK PINK BKOR WT
BR BROWN WT RD RED WT
. GAUGE O F WIRE
(18 Gouge) DB WT
DARK TN TAN WT
BLUE
P A R T O F M A I N CIRCUIT
(Varies Depending on Equipment) DG DARK WT VT VIOLET WT
GREEN
— ^ M A I N CIRCUIT IDENTIFICATION
918W-16 GY GRAY BK WT WHITE BK
LB LIGHT BK YL YELLOW BK
Fig. 3 Wire Color Code Identification BLUE
In certain instances a wire may be referenced to
LG LIGHT BK * W I T H TRACER
another sheet. When this happens, the wire will be
GREEN
identified as to where it is going.
The index used for the diagrams is located at the 918W-136
beginning of the section. The main system and all re
lated components are covered. Fig. 4 Wire Color Code Chart
CIRCUIT IDENTIFICATION
WIRE CODE IDENTIFICATION All circuits in the diagrams use an alpha/numeric
Each wire shown in the diagrams contains a code code to identify the wire and its function. To identify
(Fig. 3) which identifies the main circuit, part of the which circuit code applies to a system, refer to the
main circuit, gauge of wire, and color. The color is Circuit Identification Code Chart. This chart shows
shown as a two letter code which can be identified by the main circuits only and does not show the second
referring to the Wire Color Code Chart (Fig. 4). If ary codes that may apply to some models.
the wire has a tracer and it is a standard color an
asterisk will follow the main wire color. If the tracer LOCATING A S Y S T E M
is non-standard the main wire color will have a slash To locate a system or component in the diagrams,
(/) after it followed by the tracer color. refer to the alphabetical index at the front of the di
agrams. Determine the diagram sheet number. Sheet
MAIN CIRCUIT IDENTIFICATION
CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION
A Batter/ Feed: Fused and Unfused P Power Assist System: Locks, Mirrors
B ABS System Q Power Assist System: Windows
C Air Conditioning System R Airbag System
D CCD (+), CCD (-) S Air Suspension, Automatic Load Leveling
E Interior Lamp Illumination T Electronic Automatic Transaxle
F Battery Feed: Fused and Unfused V Windshield Wipers and Washers,
G Sensors, Sending Units, Switches Vehicle Speed Control System
K Powertrain Central Module W Power Assist System: Windows
L Exterior Lighting, Stop Lamp Switch X Horn, Radio, Radio Speakers, Power Locks
M Interior Lamps Z Ground Circuits: Includes power and signal
grounds for PCM
938W-17
WIRING DIAGRAMS 8W - 3
numbers are located at the lower right or left hand (2) Verify any related symptoms. Do this by perform
corner of each sheet. Page numbers at the top of ing operational checks on components that are in the
the page do not apply to diagram sheets. same circuit as the problem area. Refer to the wiring di
The index identifies the main system and all com agrams fuse application chart for more information.
ponents that relate to that system. There are also (3) Analyze the symptoms. Use the wiring dia
sections of the index that identify specific compo grams to determine what the circuit is doing, where
nents only (for example modules, lamps, etc.). Refer the problem most likely is occurring and where the
to a components name in the index if you are unclear diagnosis will continue.
as to what a system may be called. (4) Isolate the problem area.
Diagram sheets are arranged starting with the bat (5) Repair the problem.
tery and fuses. Then working into charging, starting, (6) Verify proper operation. For this step check for
and ignition systems. After this they start at the front proper operation of all items on the circuit repaired.
of the vehicle and work to rear of the vehicle. The dia Refer to the wiring diagram fuse application chart at
grams end with connector identification pages. the beginning of the wiring diagrams.
COMPONENT IDENTIFICATION FUSIBLE LINKS

When looking for a components actual location on the Vehicle wiring harnesses are equipped with fusible
vehicle refer to the wiring and components section in links to protect against harness damage in the event
dex. This section shows the wire harness routing and of a short in the system. Fusible links are color coded
the components location in the vehicle. When using this to indicate wire gauge and size. Refer to the fusible
section refer to the wiring diagrams for the general lo link chart for color and gauge identification (Fig. 6).
cation of the component. Then use the component iden
tification index to locate the proper figure number. W i r e mmd Cl&uge C o l o r Code Color
12 G o . BK Black
S P L I C E LOCATIONS
Splice locations are indicated in the diagrams by a 14 G o . RD Red
diamond with a splice circuit code within it (Fig. 5 16 G o . DB Dark Blue

example 1). If there is more than one splice per cir
18 G o . GY Gray
cuit a small box will be connected to it with the
splice number in it (Fig. 5 example 2). 20 G o . OR Orange
To locate a particular splice in the wiring harness de 22 G o . WT White
termine the splice number from the wiring diagrams 918W-19
then refer to the splice location index. This section
shows the general location of the splice in the harness. Fig. 6 Fusible Link Chart
HARNESS REPAIR
FUSIBLE LINK REPLACEMENT
CAUTION: Do not replace blown fusible links with a

standard wire. Only use fusible type wire with hyp-
alon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wir
EXAMPLE 1 EXAMPLE 2 ing i s used. Refer to the wiring diagrams f o r proper
918W-18 gauge and color.
Fig. 5 Wiring Splice Examples
CONNECTORS When a fusible link blows it is important to find
The connectors shown in the diagram sheets are out what the problem is. They are placed in the elec
viewed from the terminal end unless otherwise speci trical system for protection against shorts to ground
fied. For viewing bulkhead, powertrain control module, which can be caused by a component failure or vari
and transmission control module connectors refer to the ous wiring failures. Do not just replace the fusible
rear of the wiring diagrams. This area shows major con link to correct the problem.
nectors and identifies pin and cavity information. When diagnosing a faulty fusible link it is impor
tant to check the wire carefully. In some instances
TROUBLESHOOTING WIRING PROBLEMS the link may be blown and it will not show through
When troubleshooting wiring problems there are the insulation, the wire should be checked over its
six steps which can aid in the procedure. The steps entire length for internal breaks.
are listed and explained below. (1) Disconnect battery negative cable.
(1) Verify the problem. (2) Cut out the blown portion of the fusible link.
8W - 4 WIRING DIAGRAMS J
(3) Strip 1 inch of insulation from each end of the (3) Place a piece of heat shrink tubing over one
existing fusible link. side of the wire. Make sure the tubing will be long
(4) Place a piece of heat shrink tubing over one enough to cover and seal the entire repair area.
side of the fusible link. Make sure the tubing will be (4) Spread the strands of the wire apart on each of
long enough to cover and seal the entire repair area. the exposed wires (Fig. 7 example 1).
(5) Cut a replacement piece of fusible link approx (5) Push the two ends of wire together until the
imately two inches longer than the piece removed. strands of wire are close to the insulation (Fig. 7 ex
(6) Remove one inch of insulation from each end of ample 2).
the replacement fusible link. (6) Twist the wires together (Fig. 7 example 3).
(7) Spread the strands of wire apart on each of the (7) Solder the connection together using rosin core
exposed wires (Fig. 7 example 1). type solder only. Do not use acid core solder.
(8) Push the two ends of the wire together until (8) Center the heat shrink tubing over the joint
the strands of wire are close to the insulation (Fig. 7 and heat using a heat gun. Heat the joint until the
example 2). tubing is tightly sealed and sealant comes out of both
(9) Twist the wires together (Fig. 7 example 3). ends of the tubing.
(10) Solder the wires together using rosin core type (9) Secure the wire to the existing ones to prevent
solder only. Do not use acid core type solder. chafing or damage to the insulation.
(11) Center the heat shrink tubing over the joint (10) Connect battery and test all affected systems.
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both CONNECTOR REPLACEMENT
ends of the tubing. (1) Disconnect battery.
(12) Secure the fusible link to the existing ones to (2) Disconnect the connector that is to be repaired
prevent chafing or damage to the insulation. from its mating half.
(13) Connect battery and test all affected systems. (3) Remove connector locking wedge (Fig. 8).
CONNECTOR
CONNECTOR LOCKING , ~
O O Q X A / A
WEDGE TAB 928W-143

Fig. 8 Connector Locking Wedge Tab
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 9).
(5) Reset the terminal locking tang, if it has one.
918W-20 (6) Insert the removed wire in the same cavity on
Fig. 7 Wire Repair the repair connector.
WIRING REPAIR (7) Repeat steps four thru six for each wire in the
When replacing or repairing a wire, it is important connector, being sure that all wires are inserted into
that the correct gauge be used as shown in the wir the proper cavities. For additional connector pin out
ing diagrams. The wires must also be held securely identification refer to the wiring diagrams.
in place to prevent damage to the insulation. (8) Insert the connector locking wedge into the re
(1) Disconnect battery negative cable. paired connector.
(2) Remove 1 inch of insulation from each end of (9) Connect connector to its mating half.
the wire. (10) Connect battery and test all affected systems.
CONNECTOR (9) Spread the strands of the wire apart on each of

the exposed wires (Fig. 7 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex
ample 2).
(11) Twist the wires together (Fig. 7 example 3).
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
C O N N E C T O R LOCKING and heat using a heat gun. Heat the joint until the
LOCKING W E D G E
FINGER tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(14) Repeat steps 8 thru 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
EE I 3
928W-144
behind the connector and 2 inches past the repair.
Fig. 9 Connector Locking Finger and Locking (16) Reconnect the repaired connector.
Wedge (17) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL ASSEMBLY TERMINAL REPLACEMENT

REPLACEMENT (1) Disconnect battery.
(1) Disconnect Battery. (2) Disconnect the connector being repaired from
(2) Disconnect the connector being repaired from its mating half.
its mating half. (3) Remove connector locking wedge (Fig. 8).
(3) Cut off the existing wire connector directly be (4) Position the connector locking finger away from
hind the insulator and remove six inches of tape the terminal while pulling on the wire to remove the
from the harness. terminal from the connector (Fig. 9).
(4) Stagger cut all wires on the harness side about (5) Cut the wire 6 inches from the back of the con
1/2 inch apart (Fig. 10). nector.
(5) Remove 1 inch of insulation from each wire on (6) Remove 1 inch of insulation from the wire on
the harness side. the harness side.
(6) Stagger cut the matching wires on the repair (7) Select a wire from the terminal repair assem
connector assembly in the opposite order as was done bly that best matches the color wire being repaired.
on the harness side of the repair (allow extra length (8) Cut the repair wire to the proper length and re
for soldered connections). Check that the overall move 1 inch of insulation.
length is the same as the original (Fig. 10). (9) Place a piece of heat shrink tubing over one
REPAIR SIDE STAGER C U T S side of the wire. Make sure the tubing will be long
WIRES enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
of the exposed wires (Fig. 7 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(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.
HARNESS WIRES 928W-145
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge and recon
Fig. 10 Stagger Cutting Wires
nect the connector to its mating half.
(7) Remove 1 inch of insulation from each wire. (17) Re-tape the wire harness starting 1-1/2 inches
(8) Place a piece of heat shrink tubing over one behind the connector and 2 inches past the repair.
side of the wire. Make sure the tubing will be long (18) Connect battery and test all affected systems.
enough to cover and seal the entire repair area.
8W - e WIRING DIAGRAMS J
SYMBOLS, FUSES AND ABBREVIATIONS tion refer to the fuse charts and relay bank index.
Various symbols are used throughout the wiring
diagrams. These symbols can be identified by refer CAUTION: When replacing a blown fuse it i s impor
ring to the symbol identification chart (Fig. 11). tant to replace it with a fuse having the correct am
Certain abbreviations are also used in the dia perage rating. T h e use of a fuse with a rating other
grams. These have been developed in such a way than indicated may result in an electrical overload.
that there meaning should be clear. For fuse block, If a proper rated fuse continues to blow, it indicates
relay bank, and power distribution center informa a problem that should be corrected.
J W I R I N G DIAGRAMS 8W - 7
LEGEND OF SYMBOLS U S E D ON W I R I N G DIAGRAMS
+ POSITIVE CONNECTOR
— NEGATIVE MALE C O N N E C T O R
_I_
GROUND > FEMALE CONNECTOR
FUSE DENOTES WIRE CONTINUES ELSEWHERE

S
D E N O T E S W I R E GOES T O O N E OF TWO
G A N G F U S E S W I T H B U S S BAR
CIRCUITS
CIRCUIT B R E A K E R SPLICE
-K-
CAPACITOR <SljlJ SPLICE I D E N T I F I C A T I O N
n
•-AAA-*
OHMS
RESISTOR |
cftP
TIMER |
THERMAL ELEMENT
TIMER
VARIABLE R E S I S T O R MULTIPLE CONNECTOR

'YYY'
WIRING WITH
SERIES RESISTOR OPTIONAL
o-i WIRING WITHOUT
COIL
Y " Y " WINDINGS
-\J&>—<• S T E P U P COIL DIGITAL READOUT

ooooJ BB'-BB
O P E N CONTACT SINGLE FILAMENT LAMP
CLOSED CONTACT D U A L F I L A M E N T LAMP
CLOSED SWITCH L.E.D. - LIGHT EMITTING DIODE
OPEN SWITCH — THERMISTOR
:c: CLOSED GANGED S W I T C H GAUGE
OPEN GANGED SWITCH SENSOR
T W O POLE SINGLE T H R O W SWITCH ^ ' FUEL INJECTOR
M #36 DENOTES W I R E GOES T H R O U G H

PRESSURE SWITCH
BULKHEAD DISCONNECT
#19 r— 1 DENOTES WIRE GOES THROUGH

SOLENOID SWITCH STRG STEERING COLUMN CONNECTOR
" ~ ° COLUMN "~™""
—ST* DENOTES WIRE GOES THROUGH

# U
MERCURY SWITCH Ml
PANEL INSTRUMENT PANEL CONNECTOR
p— 1#7 DENOTES WIRE GOES THROUGH GROMMET

DIODE OR RECTIFIER ENG
TO ENGINE COMPARTMENT
BY-DIRECTIONAL Z E N E R DIODE DENOTES WIRE GOES THROUGH GROMMET
O MOTOR HEATED GRID ELEMENTS
0 ARMATURE AND BRUSHES

908W-191
Fig. 11 Symbol Identification

8W - 8 W I R I N G DIAGRAMS
FUSE CHARTS AND RELAY BANKS
INDEX
page
Fuse Panel XJ 9 Power Distribution Center Y J
Fuse Panel Y J 10 Power Distribution Center XJ
CAVITY AMP/COLOR ITEMS FUSED CAVITY AMP/COLOR ITEMS FUSED
20 AMP
1 Rear Window W i p e r 13 Not Used
YL
2 Not Used 14 Not Used
15 Amp
3 Key-In Switch, Stop Lamps 15 Not Used
LT BL
15 Amp 16 Not Used

4 Turn Signals
LT B L
AMPS FUSE COLOR CODE

2 0 Amp Automatic Shut-Down Relay, Fuel Pump
5
YL Relay, P.C.M. 5 TN Tan
TURN SIGNAL 15 LT BL Light Blue

25 Amp HAZARD FLASHER
6 Heated Rear Window 20 YL Yellow
NAT FLASHER
25 NAT Natural
20 Amp 30 GN Green
7 Cigar Lighter, Radio
YL
20 Amp
8 Headlamp Switch, Side Marker Lamps, Radio
YL
Combination Buzzer, Warning Lamps, Gauges,

15 Amp
9 Heated Rear Window Relay, Back-up Lamps,
LT BL
A/C Compressor Clutch Relay
10
5 Amp
TN
Instrument Panel Illumination Lamps
c
5.3 Amp
11 Windshield Wipers/Windshield Washer
C/BRKR
CIRCUIT
BREAKER
2 5 Amp
12
NAT
Blower Motor COMBINATION
BUZZER
J938W-142
Fig. 1 Fuse Panel YJ

CAVITY AMP/COLOR ITEMS FUSED CAVITY AMP/COLOR ITEMS FUSED
25 AMP 25 AMP
1 REAR W I P E R , REAR WASHER 18 HEATED REAR W I N D O W
NAT NAT
15 A M P R A D I O , R A D I O CLOCK I L L U M I N A T I O N , 5 AMP
2 19 INSTRUMENT PANEL LAMPS
LT BL CIGAR L I G H T E R , D O M E L A M P TN
5.5 A M P
3 NOT USED 20 WINDSHIEND WIPER/WINDSHIELD WASHER
C/BRKR
15 A M P AMPS FUSE COLOR CODE

4 F L A S H T O PASS
LT BL
2 PK PINK
25 AMP
5 BLOWER MOTOR 5 TN TAN
NAT
COMBINATION 7.5 VT VIOLET
30 A M P BUZZER
6 POWER WINDOWS
C/BRKR 10 RD RED
2 AMP 15 LT BL LIGHT BLUE

7 ANTILOCK BRAKES
PK
20 YL YELLOW
20 AMP
8 T U R N SIGNAL FLASHER 25 NAT NATURAL
YL
TURN
10 AMP ILLUMINATED ENTRY, RADIO, COURTESY SIGNAL
9
RD L I G H T S , G L O V E BOX; C A R G O ; D O M E L A M P S FLASHER
10 NOT USED
25 AMP
11 H E A D L A M P DELAY M O D U L E , H O R N S
NAT
12 NOT USED
13 NOT USED
5.5 A M P
10 AMP C/BRKR
14 POWER ANTENNA
RD
15 A M P L P . L A M P S , CLOCK, R A D I O / C L O C K
15
LT BL ILLUMINATION, REAR LAMPS, F R O N T LAMPS
30 A M P .HAZARD
16 POWER SEATS, TRAILER T O W FLASHER
C/BRKR
7.5 AMP I N S T R U M E N T CLUSTER GAUGES, HEADLAMP

17
VT DELAY M O D U L E , C H I M E M O D U L E
J938W-143
Fig. 2 Fuse Panel XJ

WIRING DIAGRAMS 8W - 1 1
FUSE AMPS COLOR DESCRIPTION TYPE FUSE AMPS COLOR DESCRIPTION TYPE
F1 30 Green Fuel Pump/Automatic Shutdown Maxi F9 40 Amber A B S Pump Relay Maxi
F2 50 Red Charging Maxi F10 30 Green A B S Power Relay Maxi
F3 50 Red Battery Acc. Feed Maxi Fll
F4 40 Amber Ignition/Engine Starter Feed Maxi F12
F5 20 Yellow Hazard Flasher Feed Maxi F13 2 Gray A B S Control Module Mini
F6 50 Red Charging Maxi F14
F7 30 Green Headlamp Feed Maxi F15 10 Red Horn/Horn Relay Mini
F8 20 Yellow I.O.D./Horn Feed Maxi F16 10 Red I.O.D.
RELAYS
} CEO m
c } CjilD C U D F9
J938W-144
Fig. 3 Power Distribution Center YJ

RELAYS
J938W-145
Fig. 4 Power Distribution Center XJ

J W I R I N G AND COMPONENT IDENTIFICATION 8W - 13
WIRING AND COMPONENT IDENTIFICATION
CONTENTS
page page
XJ . 25 YJ . 13
The wiring and components shown in this section ber that refers to the component. Page numbers at
are divided into sections by vehicle line. When locat the top of the page do not refer to figure num
ing a specific wire routing or component, first turn to bers.
the appropriate index, then look up the figure num
YJ
Caption Fig. Caption ^ Fig.
Battery and Starter Wiring .8 Engine Wiring 4.0L 11
Body Wiring ...1,2 Front End Wiring . 12
Chassis Wiring . 3 Instrument Panel Wiring 5, 6
Engine Compartment Wiring 7 Steering Column Wiring 4
Engine Wiring 2.5L 10 Transmission Wiring 9
T O PARKING BRAKE
TO INSTRUMENT
SWITCH
PANEL W I R I N G
PARK BRAKE
SWITCH
CONNECTOR
EE
a.
>
o
o
o
o
T O LEFT m
TAILLAMP
ASSEMBLY o
>
T O LICENSE
PLATE
LAMPS
REAR W A S H E R
HOSE T O A B S CONTROL MODULE
BEYOND T H I S POINT
SEE M A I N V I E W
V I E W IN DIRECTION
OF A R R O W S
J938W-119
Fig. 1 Body Wiring YJ

8W - 18 WIRING AND COMPONENT IDENTIFICATION J
Fig. 3 Chassis Wiring YJ
J918W-54
Fig. 4 Steering Column Wiring YJ

T O FUSEBLOCK
TO BLOWER MTR REAR SPEAKER
JUMPER
T O I/P CONNECTOR
T O BODY H A R N I & II
T O T U R N SIGNAL
H E A T E R LIMIT S W I T C H
ILLUMINATION
LAMP
T O DOOR S W I T C H
SEE VIEW X
INSTRUMENT
xyS PANEL
SPEAKER
GAUGE
PACKAGE
V I E W I N DIRECTION
OF A R R O W V
OF A R R O W X
T O REAR (LT SIDE S H O W N )
(RT SIDE S H O W N LT SIDE TYPICAL)
SPEAKERS (RT SIDE TYPICAL)
J938W-121
Fig. 5 Instrument Panel Wiring YJ

TO WIPER SWITCH
T O A/C
SEE V I E W Y
FUSEBLOCK
GROUND
HEADLAMP
SWITCH
CONNECTOR
LEFT COURTESY
LAMP
OF A R R O W H T O H E A T E D REAR OF A R R O W S
W I N D O W SWITCH
J938W-122
Fig. 6 Instrument Panel Wiring YJ

c
BRAKE
WARNING
SWITCH
J938W-123
Fig. 7 Engine Compartment Wiring YJ

8 W - 20 WIRING AND COMPONENT IDENTIFICATION
BATTERY
T O BODY
GROUND
TO
ENGINE
GROUND
TOWER
DISTRIBUTION
CENTER FEED
TERMINAL
ENGINE
STARTER
J938W-124
Fig. 8 Battery and Starter Wiring YJ
VACUUM
FRONT
AXLE
DISCONNECT
HARNESS
4WD
INDICATOR
SWITCH
CONNECTOR
OF ARROW Y
NEUTRAL-START DISTANCE
SWITCH SENSOR
J918W-57
Fig. 9 Transmission Wiring YJ

E N G I N E COOLANT
GROUND T O MAP S E N S O R
TEMPERATURE SENSOR
(GAUGE)
FUEL
INJECTOR #4
E N G I N E COOLANT FUEL
TEMPERATURE FUEL INJECTOR
SENSOR INJECTOR #2
DISTRIBUTOR
E N G I N E OIL PRESSURE
SENDING UNIT/SWITCH
GENERATOR
22
a
>
o
o
o
2
•o
o
z
T O ENGINE
CRANKSHAFT STARTER
POSITION o
SENSOR
o
J938W-125
Fig. 10 Engine Wiring Z5L YJ

FUEL FUEL GROUND . E N G I N E COOLANT
THROTTLE FUEL i T O R #5 INJECTOR #6
N J E C
, f N J t u O R # 5 TEMPERATURE !S3
BODY IDLE AIR INJECTOR #4
SENSOR
CONTROL (GAUGE)
MOTOR
T O MAP
SENSOR
22
THROTTLE a
POSITION >
(SENSOR) z
o
o
o
2
INTAKE AIR
-o
TEMPERATURE
o
SENSOR m
HEATED m
OXYGEN
SENSOR
>
CRANKSHAFT
POSITION
SENSOR
TO TRANSMISSION
WIRING ENGINE
STARTER
J938W-126
Fig. 11 Engine Wiring 4.0L YJ

REAR WASHER
PUMP MOTOR
Fig. 12 Front End Wiring YJ

8 W - 24 WIRING AND COMPONENT IDENTIFICATION
J WIRING AND COMPONENT IDENTIFICATION 8 W - 25
XJ
Caption ; Fig. Caption Fig.
Anti-Lock Brake System Wiring XJ 3 Instrument Panel Wiring XJ .12, 13
Body Wiring XJ 7, 8 Liftgate Wiring XJ 1
Door Wiring (Front) XJ .11 Power Seat Wiring XJ .15
Engine Compartment Wiring 2.5L XJ . 17 Rear Door Wiring XJ 6
Engine Compartment Wiring 4.0L XJ 18, 19 Roof Wiring (Rear) XJ 9
Engine Wiring 2.5L XJ 21 Roof Wiring XJ . . . . . . . . . . 5
Engine Wiring 4.0L XJ 22 Steering Column Wiring XJ . . . . 10
Front Crossbody Wiring XJ . .4 Trailer Tow Wiring XJ 2
Front End Wiring XJ 16 Transmission Wiring XJ 20
Instrument Panel to Body Wiring XJ .14
8W - 26 WIRING AND COMPONENT IDENTIFICATION
TOHEATED
REAR
WINDOW
J928W-18
Fig. 1 Liftgate Wiring XJ
CONNECTOR
TRAILER T O W
HARNESS
J938W-128
Fig. 2 Trailer Tow Wiring XJ

Fig. 4 Front Crossbody Wiring XJ

V I E W IN DIRECTION PANEL W I R I N G
OF ARROW Y
J938W-132
Fig. 5 Roof Wiring XJ

Fig. 6 Rear Door Wiring XJ
VIEW IN DIRECTION VIEW IN DIRECTION WIRING
OF ARROW V OF ARROW X
J938W-133
Fig. 7 Body Wiring XJ 6.

Fig. 8 Body Wiring XJ
J928W-25
Fig. 9 Roof Wiring (Rear) XJ

- 32 WIRING AND COMPONENT IDENTIFICATION J
Fig. 10 Steering Column Wiring XJ
CONNECTOR
J938W-135
Fig. 11 Door Wiring (Front) XJ

TO MODE SWITCH T O RADIO & GROUND
T O ILLUMINATION LAMP
T O GLOVE BOX SWITCH TO CLUSTER
T O HEATED REAR
W I N D O W A N D FOG
LAMP SWITCH
ILLUMINATION
TO HEADLAMP
SWITCH
GROUND
TO LEFT
COURTESY LAMP
TO LEFT
I/P SPEAKER
TO LEFT FRONT
DOOR J A M B S W I T C H
T O L E F T DOOR
S P E A K E R (MJ)
T O CAB H A R N E S S
T O PARKING BRAKE SWITCH
T O L E F T DOOR
SPEAKER
(XJ)
T O BODY HARNESS
T O RIGHT REAR
DOOR S W I T C H
FUSEBLOCK
J938W-136
Fig. 12 Instrument Panel Wiring XJ

GLOVE BOX INTERMITTENT
LAMP A N D WIPER MODULE
SWITCH
INSTRUMENT
PANEL
SWITCH
MODULE
FOG L A M P
SWITCH
SWITCH
MODULE
REAR WIPER
SWITCH
OF ARROW X V I E W IN DIRECTION
OF ARROW R
VIEW V
J928W-28
F i g . 13 Instrument Panel Wiring XJ

TO LEFT TO PARK T O RELAY T O CAB W I R I N G MAIN VIEW T O IGNITION BEYOND THIS
TO MULTI-FUNCTION SWITCH POINT SEE
I/P SPEAKER BRAKE CENTER (MJ ONLY)
SWITCH VIEWZ
TO LEFT
COURTESY
LAMP
STOP
TO LEFT SEE V I E W X LAMP
FRONT SWITCH
JAMB SWITCH
LEFT FRONT
DOOR
SPEAKER FUSE PANEL
CONNECTOR TAPS
STEERING
:TO CROSSBODY
COLUMN
HARNESS
I/P T O
BODY A/C
OF ARROW Z FRONT
CONNECTOR THERMOSTAT
ROOF
ABS CONTROL
ABS CONTROL WIRING
MODULE
MODULE CONNECTORS
BLOWER
PARK BRAKE MOTOR
GROMMET RESISTOR
WARNING
SWITCH CONNECTOR
BEYOND THIS
POINT SEE
MAIN VIEW
PARKING
BRAKE
LEVER RIGHT
VIEWU FRONT
(MJ ONLY) VEHICLE
HEATER DOOR
SPEED
DUCT CONNECTOR
CONTROL
CONNECTOR
V I E W I N DIRECTION
V I E W IN DIRECTION OF ARROW Y
OF ARROW X
J938W-137
Fig. 14 Instrument Panel to Body Wiring XJ

8W - 3 i WIRING AND COMPONENT IDENTIFICATION J
SEAT
SWITCH
BEZEL
Fig. 15 Power Seat Wiring XJ
OF ARROW Y J928W-31
Fig. 16 Front End Wiring XJ

BALLAST DATA L I N K
VEHICLE S P E E D WINDSHIELD RESISTOR CONNECTOR
CONTROL SERVO WIPER MOTOR POWERTRAIN
CONTROL
MODULE
TO FRONT END
BEYOND THIS POINT LIGHTING
SEE V I E W U
OF ARROW V
T O ENGINE
WIRING
T O B U L K H E A D DISCONNECT
BEYOND THIS POINT
LOW WASHER
HI-NOTE F L U I D LEVEL UNDERHOOD POWER DISTRIBUTION
HORN \ SENSOR LAMP CENTER
V I E W IN DIRECTION -
OF ARROW Z AAAP S E N S O R
TO INSTRUMENT LO-NOTE HORN
PANEL W I R I N G
BATTERY FEED DAYTIME

T O P.D.C. BALLAST RUNNING LAMP
RESISTOR MODULE
B Y - P A S S RELAY ( C A N A D A ONLY)
OF ARROW U
BLOWER
MOTOR
^ 3
POWER fft OF ARROW X
T O TRANSMISSION
DISTRIBUTION
WIRING
CENTER J938W-138
F i g . 17 Engine Compartment Wiring 2.5L XJ

WASHER FLUID UNDERHOOD
BLOWER
LEVEL S W I T C H LAMP
MOTOR
CONNECTOR
WASHER
MAP
FLUID
SENSOR
BOTTLE
(PUMPS SEE
LOCATED VIEW R
A T REAR)
B +
FEED
TERMINAL
DAYTIME RUNNING
LAMP MODULE
TO
INSTRUMENT
PANEL HARNESS
VEHICLE
SPEED
CONTROL
SERVO
TO P.D.C.
BATTERY
A/C LOW V I E W IN DIRECTION
POWER ABS RIGHT OF ARROW W
PRESSURE
DISTRIBUTION FRONT WHEEL SWITCH
CENTER SENSOR
(P.D.C.) BALLAST
CONNECTOR
RESISTOR
WINDSHIELD BY-PASS
WIPER MOTOR DASH RELAY
PANEL P.D.C.
RECEIVER
DRIER
TO
ENGINE
HARNESS
V I E W IN DIRECTION HORN
WINDSHIELD OF ARROW R V I E W IN DIRECTION
WIPER OF ARROW S
MOTOR
OF ARROW Y
CONNECTOR
Fig. 18 Engine Compartment Wiring 4.0L XJ

FUEL PUMP ABS
BALLAST DATA L I N K T O HEADLAMP
LEFT FRONT CONNECTOR
RESISTOR WHEEL SENSOR AND DASH
CONNECTOR HARNESS
TO
BULKHEAD
CONNECTOR
BULKHEAD
DISCONNECT
BRAKE
WARNING
SWITCH
2
o
HYDRAULIC
ACTUATOR
>
CONNECTOR o
o
o
ABS z
ASSEMBLY •HO
O
Z
ffi
o
PEDAL rn
Z
TRAVEL
BRAKE
SENSOR
WAKNING
SWITCH
(ABS)
VIEW IN DIRECTION
OF ARROW P
J938W-140
Fig, 19 Engine Compartment Wiring 4.0L XJ

AND MANUAL
J938W-141
Fig. 20 Transmission Wiring XJ c

E N G I N E COOLANT
TEMPERATURE SENSOR GROUND T O MAP S E N S O R
(GAUGE)
E N G I N E COOLANT
TEMPERATURE
SENSOR
DISTRIBUTOR
E N G I N E OIL P R E S S U R E
SENDING UNIT/SWITCH
GENERATOR
CRANKSHAFT T O ENGINE
POSITION STARTER
SENSOR
OF A R R O W X
J938W-125
Fig. 21 Engine Wiring 2.5L XJ

FUEL GROUND ^ E N G I N E COOLANT
FUEL
THROTTLE
F U E L
INJECTOR f#5
I N J t u U R
5 INJECTOR #6 TEMPERATURE
INJECTOR #4 SENSOR
BODY FUEL (GAUGE)
INJECTOR #3
T O MAP S
SENSOR
=5
THROTTLE o
POSITION >
(SENSOR) z
o
o
o
INTAKE AIR o
TEMPERATURE z
SENSOR
HEATED
OXYGEN
SENSOR
o
>
CRANKSHAFT
POSITION
SENSOR
TO TRANSMISSION
ENGINE
WIRING
STARTER
J938W-126
Fig. 22 Engine Wiring 4.0L XJ

J SPLICE LOCATIONS 8 W - 43
SPLICE LOCATIONS
The splice locations shown in this section are di- then look up the figure number that refers to the
vided into sections by vehicle line. When locating a splice. Page numbers at the top of the page do
specific splice first, turn to the appropriate index, not refer to figure numbers.
Y J SPLICE LOCATIONS
Splice Number Fip^ Splice Number Fio^
A6 2 L7 2
A11 4 L7-1 5
A142 3 L7-2 1
A142-1 3 L39 6
B15 4 M1 2
E2 2 MM 4
F15 4 M2 2
F30 . .2 Z1 2
65 2 Z1-2 2
G7 3 Z1-3 2
G19 4 Z1-5 1
G50 4 Z1-6 1
K4 3 Z1-7 3
K4-1 3 Z1-8 4
K6 3 Z1-9 . 5
K7 3 ZMO 5
L1 1 Z12 4
L3 Canada Only 5 Z2 3
L4 Canada Only 6
8 W - 44 S P L I C E LOCATIONS
J
J938W-66
Fig. 2 Instrument Panel Splices YJ

- 46 SPLICE LOCATIONS J
Fig. 5 Front End Splices YJ

Fig. 6 Front End Splices YJ
8W - 48 SPLICE LOCATIONS
J SPLICE LOCATIONS 8 W- 49
X J SPLICE LOCATIONS
Caption Fijk Caption Fip^
117 10 K7 4.0L 15
235 11 K22 4.0L 11
A3 9 K29 11
A11 11 L90 3
A11-1 3 L90-1 10
A14 11 M1 6
A21 11 M1-1 8
A21-1 9 M2 8
A38 9 M2-1 9
A142 2.5L 13 P2 3
A142 4.0L 15 P34 3
A142-1 11 P79 4
A142-2 2.5L 13 Q1 4
A142-2 4.0L 14 Z1 6
C7 8 Z1-1 3
C15 9 Z1-2 8
C43 8 Z1-3 9
C90 11 Z1-4 12
E2 8 Z1-5 1
F12 11 Z1-10 10
F34 8 Z1-11 11
F85 8 Z1-12 11
G7 11 Z1-13 4
K4 2.5L 13 Z1-14 7
K4 4.0L 15 Z11 4.0L 12
K4-1 11 Z12 11
K6 11 Z12-1 11
K7 2.5L 13
8W - 50 S P L I C E LOCATIONS J
Fig. 2 Body Splices XJ

J SPLICE LOCATIONS 8W - 51
Fig. 6 instrument Panel Splices XJ
J SPLICE LOCATIONS 8 W - 13
Fig. 7 instrument Panel Splices XJ
J928W-74
Fig. 8 Front End Splices XJ

8W - 54 SPLICE LOCATIONS J
Fig. 10 Engine Compartment Splices XJ

SPLICE LOCATIONS 8W • 55
J
J938W-251
Fig. 12 Engine Splices 4.0L XJ

J938W-252
Fig. 13 Engine Splices 4.0L XJ

WIRING DIAGRAMS Y J
INDEX
Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number
ABS Accelerator Sensor 56 Charging System 4.0L Engine .5, 6
ABS Control Module 56, 57, 58 Battery 5
ABS Control Module Connector 59 Generator .5
ABS Motor Pump Relay 57 Power Distribution Center 6
ABS Power Relay .57 Cigar Lighter 24
A/C Blower Switch 50 Circuit Breakers
A/C Compressor 49 Headlamp Switch 29
A/C Low Pressure Switch 49 #11 (W/Wiper) 2, 10, 38, 39
A/C Relay 49 Clock 45
A/C Thermostat .50 Cluster Connector 41
Accessory Illumination .32 Crankshaft Position Sensor 12, 18
Air Conditioning System (4.0L) .49, 50 Data Link Connector 13, 19, 57
A/C Blower Switch 50 Daytime Running Lamp Module 28
A/C Compressor 49 Dimmer Switch 1 , 29
A/C Low Pressure Switch 49 Dome and Courtesy Lamps 35
A/C Relay 49 Dome Lamp 35
A/C Thermostat .50 Left Courtesy Lamp .35
Field Jumper 50 Left Front Door Jam Switch 35
Powertrain Control Module 49 Right Courtesy Lamp 35
Anti-Lock Brake System (TEVES) 56, 57, 58 Right Front Door Jam Switch 35
ABS Accelerator Sensor . .56 Dome Lamp 35
ABS Control Module 56, 57, 58 Electrically Tuned Radio with Clock .45
ABS Motor Pump Relay 57 Electrical Schematic of Cluster 42
ABS Power Relay 57 Electrical Schematic of Gauge Package 44
Brake Pedal Travel Sensor 57 Electronic Speedometer 42
Data Link Connector .57 Electronic Tachometer 42
Diode 58 Engine Coolant Temp Gauge 44
Hydraulic Actuation Unit 58 Engine Coolant Temperature Sensor 15, 21
Left Front Wheel Sensor . .56 Engine Oil Pressure and Temperature System . 23
Left Rear Wheel Sensor 56 Engine Coolant Temperature Sending Unit 23
Power Distribution Center 57 Engine Oil Pressure Sending Unit 23
Pump Motor 57 Engine Oil Pressure Gauge .44
Pump Motor Sensor 57 Engine Starter System 2, 7
Right Front Wheel Sensor 56 Back-Up Lamp Switch 7
Right Rear Wheel Sensor 56 Back-Up, Park/Neutral Position (Switch) 7
Automatic Shut-Down Relay 1 1 , 17 Engine Starter Motor 7
Back-Up Lamps 5 1 , 52 Engine Starter Relay 7
Back-Up Lamp Switch -7 Engine Wiring Connector (16 Way) 69
Back-Up/Park/Neutral Position (Switch) 7 4-WD Command Trac Switch . 8
Battery 1 , 3, 5 Field Jumper 50
Blower Motor 47 Fog Lamp Switch 30
Blower Resistor .47 Front End Lighting 25, 26
Blower Switch 47 Left Fog Lamp 25
Body Harness Connector 36 Left Headlamp .25
Brake Pedal Travel Sensor 57 Left Park and Turn Signal Lamp 25
Brake Warning Switch 9 Left Side Marker Lamp 25
Bulkhead Connector . .65, 66 Right Fog Lamp 26
Buzzer Module 36 Right Headlamp 26
Camshaft Position Sensor 12, 18 Right Park and Turn Signal Lamp 26
Charging System 2.5L Engine .3, 4 Right Side Marker Lamp 26
Battery • 3 Front End Lighting (Canada) . .27, 28
Generator -3 Daytime Running Light Module 28
Power Distribution Center 4 Left Fog Lamp 27
Wiring Diagram Name Sheet Number

J
Left Headlamp 27 11 2, 10, 38, 39
Left Park and Turn Signal Lamp .27 12 2, 10, 47, 48, 50
Left Side Marker Lamp 27 F13 2, 58
Right Fog Lamp .28 F15 . • .2, 4, 6, 33
Right Headlamp .28 F16 2, 4, 6, 8, 35
Right Park and Turn Signal Lamp 28 Fuse Panel 61, 62
Right Side Marker Lamp 28 Gauge Package Connector 43
Fuel Gauge 44 Gauges
Fuel Injectors .14, 20 Electronic Speedometer 42
Fuel Injection Ignition System Electronic Tachometer 42
2.5L Engine . . . . . . . . . . . . . . . .11, 12, 13, 14, 15, 16 Engine Coolant Temp Gauge 44
Automatic Shut Down Relay .11 Engine Oil Pressure Gauge .44
Camshaft Position Sensor 12 Fuel Gauge 44
Crankshaft Position Sensor 12 Voltmeter 44
Data Link Connector 13 Generator 3, 5
Engine Coolant Temperature Sensor 15 Hazard Signal Flasher .34
Fuel Injectors 14 Headlamps • .25, 26, 27, 28
Fuel Pump Relay . .11 Headlamp Switch . . . 1 , 29, 30
Heated Oxygen Sensor .11 Dimmer Switch 29
Idle Air Control Motor .14 Fog Lamp Switch • 30
Ignition Coil . .13 Headlamp Switch 29
Intake Air Temperature Sensor 15 Heated Oxygen Sensor 1 1 , 17
MAP Sensor .15 Heated Rear Window .53
Power Steering Switch 14 Heated Rear Window Switch .53
Powertrain Control Module (PCM) . . 1 1 , 12, 13, 14, 15, 16 Heater Control Panel Illumination 32
Throttle Position (Sensor) 15 Heated Rear Window Relay .54
Vehicle Speed Sensor 12 Heated Rear Window Switch . .53
Fuel Injection Ignition System Heated Rear Window System 53, 54
4.0L Engine 17, 18, 19, 20, 2 1 , 22 Heated Rear Window .53
Automatic Shut Down Relay .17 Heated Rear Window Switch .53
Camshaft Position Sensor 18 Heated Rear Window Relay 54
Crankshaft Position Sensor 18 Timer .54
Data Link Connector 19 Heater System .47
Engine Coolant Temperature Sensor 21 Blower Motor .47
Fuel Injectors 20 Blower Resistor . .47
Fuel Pump Relay .17 Blower Switch 47
Heated Oxygen Sensor 17 Heater/Off Switch 47
Idle Air Control Motor 20 Horn 33
Ignition Coil • -19 Horn Brush/Slip Ring 33
Intake Air Temperature Sensor . 21 Horn Relay - • -33
MAP Sensor • 21 Horn Switch • 33
Powertrain Control Module (PCM) . .17, 18, 19, 20, 2 1 , 22 Hydraulic Actuation Unit 58
Throttle Position (Sensor) 21 Idle Air Control Motor 14, 20
Vehicle Speed Sensor .18 Ignition Coil -13, 19
Fuel Pump Relay . 1 1 , 17 Ignition Key Warning Switch 36
Fuel Tank System .55 Ignition Switch 2, 9, 10
Fuel Tank Sending Unit 55 Instrument Panel Illumination Lamps .32
Fuse Application Chart 1,2 Intake Air Temperature Sensor 15, 21
Fuses Intermittent Wiper Module • • -40
1 2, 10, 37 Intermittent Wiper System 39, 40
3 . . 1 , 30, 34, 36 Intermittent Wiper Module 40
4 2, 10, 34 Park Switch .39
5 .2, 10, 13, 19 Washer Pump 39
6 1 , 30, 53 Wiper Motor 39
7 2, 10, 24, 46 Wiper/Washer Switch 40
8 1 , 29 W/Wiper Circuit Breaker (5.3 Amp) . .39
9 . .2, 10, 36 Lamps
10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 , 3 1 Dome Lamp .35
J WIRING DIAGRAMS 8 W - 59
Instrument Panel Illumination Lamp .32 Radio Illumination Relay 45
Left Back-Up Lamp .51 Radio System 45, 46
Left Courtesy Lamp . .35 Electrically Tuned Radio with Clock 45
Left Fog Lamp .25, 27 Left Front Speaker 46
Left Headlamp 25, 27 Left Halo Speaker . . 46
Left Park and Turn Signal Lamp .25, 27 Radio Illumination Relay 45
Left Side Marker Lamp .25, 27 Right Front Speaker 46
Left Tail, Stop and Turn Signal Lamp 51 Right Halo Speaker 46
License Lamp 51 Rear Lighting . 5 1 , 52
Right Back-Up Lamp . .52 Left Back-Up Lamp 51
Right Courtesy Lamp . .35 Left Tail, Stop & Turn Signal Lamp & License Lamp . . .51
Right Fog Lamp . . . .26, 28 Right Back-Up Lamp 52
Right Headlamp . . . . .26, 28 Right Tail, Stop & Turn Signal Lamp .52
Right Park and Turn Signal Lamp 26, 28 Rear Wiper/Washer System .37
Right Side Marker Lamp 26, 28 Rear Wiper Motor 37
Right Tail, Stop and Turn Signal Lamp 52 Rear Wiper Switch 37
Underhood • . -8 Washer Pump 37
Left Back-Up Lamps 51 Relays
Left Courtesy Lamp 35 A/C 49
Left Fog Lamp • .25, 27 ABS Motor Pump Relay 57
Left Front Speaker . . 46 ABS Power Relay 57
Left Halo Speaker .46 Automatic Shut Down Relay 1 1 , 17
Left Headlamp 25, 27 Engine Starter Relay 7
Left Park and Turn Signal Lamp .25, 27 Fuel Pump Relay . 1 1 , 17
Left Side Marker Lamp 25, 27 Heated Rear Window Relay 54
Left Tail, Stop and Turn Signal Lamp .51 Horn Relay . 33
Left Door Jam Switch .35 Radio Illumination Relay 45
MAP Sensor 15, 21 Right Back-Up Lamp 52
Mercury Switch .8 Right Courtesy Lamp 35
Modules Right Fog Lamp 26, 28
ABS Control Module 56, 57, 58 Right Front Door Jamb Switch 35
Buzzer Module . .36 Right Front Speaker 46
Daytime Running Lamp Module 28 Right Halo Speaker 46
Intermittent Wiper Module 40 Right Headlamp . .26, 28
Powertrain Control Module 1 1 , 12, 13, 14, 15, 16, Right Park and Turn Signal .26, 28
17, 18, 19, 20, 2 1 , 22, 49 Right Side Marker Lamp . .26, 28
Motors Right Tail, Stop and Turn Signal Lamp . 52
Blower Motor .47 Seat Belt/Ignition Key Warning Buzzer . 36
Engine Starter Motor .7 Seat Belt Switch 36
Idle Air Control Motor .14, 20 Sensors
Rear Wiper Motor 37 ABS Accelerator Sensor .56
Wiper Motor .38, 39 Brake Pedal Travel Sensor 57
Oil Pressure and Temp System .23 Camshaft Position Sensor . . . . . . . . . . . . . . . . . .12, 18
Panel Lamps 3 1 , 32 Crankshaft Position Sensor . . . . . . . . . . . . . . . . . .12, 18
Accessory Illumination 32 Engine Coolant Temperature Sensor 15, 21
Heater Control Panel Illumination 32 Heated Oxygen Sensor 1 1 , 17
Panel Lamp Dimmer Switch .31 Intake Air Temperature Sensor . .15, 21
Transmission Range Illumination 32 MAP Sensor . .15, 21
Park Brake Switch .9 Pump Motor Sensor . .57
Powertrain Control Module 1 1 , 12, 13, 14, 15, 16, Throttle Position (Sensor) .15, 21
17, 18, 19, 20, 2 1 , 22, 48, 49 Vehicle Speed Sensor 12, 18
Powertrain Control Module Connector (2.5L Engine) 63 Wheel Sensors 56, 57
Powertrain Control Module Connector (4.0L Engine) 64 Speakers .46
Power Distribution Center 1 , 4, 6, 57 Speedometer .42
Power Distribution Center Identification Cover 67 Splices
Power Distribution Center Relays .68 Splice A6 30
Power Steering Switch 14 Splice A11 4, 6
Provisions for A/C (2.5L) . . . . . . . . 48 Splice A142 14, 20
Sp ce A142-1 3, 5 Switches
Sp ce B15 58 A/C Blower Switch 50
Sp ce E2 3 1 , 45 A/C Low Pressure Switch 49
Sp ce F15 58 Back-Up Lamp Switch 7
Spl ce F30 24, 45 Back-Up/Park/Neutral Position (Switch) 7
Sp! ce G5 10 Blower Switch 47
Spl ce G7 12, 18 Brake Warning Switch 9
Sp ce G19 58 Dimmer Switch 1 , 29
Sp ce G50 13, 19 Door Jam Switch 35
Sp ce K4 15, 21 4-WD Drive Switch 8
Sp ce K4-1 12, 18 Fog Lamp Switch 30
Sp! ce K6 .15, 21 Headlamp Switch 1 , 29
Sp ce K7 .12, 18 Heated Rear Window Switch 53
Sp! ce L1 .51 Heater/Off Switch 47
Sp ce L3 .28 Horn Switch 33
Spl ce L4 .28 Ignition Key Warning Switch 36
Sp ce L7 .30 Ignition Switch 1, 9
Sp lice L7-1 26, 28 Mercury Switch 8
Sp lice L7-2 51 Panel/Lamp Dimmer Switch 1 , 31
Sp lice L39 26, 28 Park Brake Switch 9
Sp lice M1 35 Power Steering Switch 14
Sp lice M M 8, 35 Rear Wiper Switch 37
Sp lice M2 35 Seat Belt Switch 36
Sp lice Z1 32 Stop Lamp Switch 34
Sp lice Z1-2 31 Washer Switch 38, 40
Sp lice Z1-3 32 Wiper/Washer Switch 38, 40
Sp lice Z1-4 54 Tachometer 42
Sp lice Z1-5 5 1 , 54 Throttle Position (Sensor) 15, 21
Sp lice Z1-6 36, 5 1 , 54 Timer 54
Sp lice Z1-7 1 1 , 17 Transmission Range Illumination 32
Sp lice Z1-8 8 Turn/Hazard Switch Assembly 34
Sp lice Z1-9 26, 28 Turn Signal Flasher 34
Sp lice Z M O 25, 27, 37 Underhood Light 8
Sp lice Z2 55 Vehicle Speed Sensor 12, 18
Sp lice Z12 57 Voltmeter 44
Starter Relay 7 Washer Pump 37, 38, 39
Starter System, Engine 7 Washer Switch 38, 40
Steering Column Connector 60 Wheel Sensors 56
Stop Lamp Switch 34 Windshield Wiper System . 38
Stop/Turn and Hazard Flasher Systems 34 Washer Pump 38
Hazard Signal Flasher 34 Washer Switch 38
Stop Lamp Switch 34 Wiper Motor 38
Turn/Hazard Switch Assembly 34 Wiper/Washer Switch 38
Turn Signal Flasher 34 W/Wiper Circuit Breaker 38
Wiper Switch 38
AO 6RD
u /kV
A n AlO A20 A14
16RD
+ l 0 R
D
D
12RD
BR
HRD
06 WT
BATTERY
A3 12R0/0R
HAZARD F U E L PUMP
FLASHER CHARGING RELAY
SH 34 SYSTEM SH 1 1 . 1 7
SH 3 . 4 . 5 . 6 AUTOMATIC S H U T DOWN
RELAY
SH 1 1 . 1 7
ENGINE CONTROL
MODULE
FUSE # 8 SH 1 1 . 1 7
(20 AMP)
•F33 18PK/RD
3*D F U S E #3
» ( 1 5 AMP)
)25A 6*3
FUSE #6
Jt/BC/B
T HEADLAMP
H
SNITCH
IT
(25 AMP)
A20
SH 29 HRD
F32 F32
F81 DO
\ 18PK 18PK
DB DB 14BR
i
K E Y - I N SWITCH
x
STOP LAMPS HEATED REAR
i ABS
BUZZER SH 34 WINDOW POWER
AlO
SH 36 SH 53 RELAY
I2RD
L2 SH 57
BR
16LG
L7 18BK/YL
1
DIMMER
SWITCH
SH 29 PANEL
LAMP ABS
DIMMER PUMP RELAY
SWITCH SH 57
TAIL/MARKER
LAMPS
SH 5 1 . 5 2
FUSE #10 PARK/MARKER
5 AMP LAMPS
SH 2 5 . 2 6 . 2 7 . 2 8
RADIO RELAY
SH 45
PANEL ILLUMINATION
LAMPS SH 31
YJ 1 FUSE APPLICATION CHART J938W-5

Al 12RD ENGINE
IGNITION
STARTER
A4 1 8 B K / R 0 —i SWITCH
SYSTEM
SH 9
SH 7
FUSE # F 1 5
(10 AMP) (RUN I START)
—A21 14DB —
A22
14BK
OR
9
HORN S Y S T E M
SH 33 S FUSE* 9
k(1 5 AMP)
(RUN)
1ZJ A31 G5 A21

F16
3
FUSE
(10
#F1G
AMP)
F13
3
FUSE # F 1 3
(2 AMP) 12
ID F U S E # 12
14BK
WT
18DB
WT
14DB
(25 AMP)
J Z3
LT
FUSE # 1
(20 AMP)
F15 V23 BUZZER
Ml CI 16BR
18YL SH 36
18PK 14DG
DG PK WARNING LAMPS
SH 41
TACH. AND
SPEEDOMETER
CLOCK ABS MODULE HEATER REAR W I P E R SH 41
SH 45 SH 58 SH 47 SH 37 GAUGES
OOME LAMPS ABS POWER R E L A Y A I R CONDITIONING SH 43
SH 35 SH 57 SH 4 8 , 50 H E A T E D REAR
COURTESY LAMPS WINDOW R E L A Y
SH 35 (RUN i ACC) SH 54
RADIO MEMORY BACK-UP LAMPS
SH 45 SH 5 1 . 52
UNDERHOOD LAMP A/C COMPRESSOR
SH 8 CLUTCH R E L A Y
ABS DATA L I N K SH 49
SH 57 D R L MODULE
SH 28
FUSE #4 FUSE # 7
(15 AMP) (20 AMP)
n
CIRCUIT
BREAKER
13 4
ZD
#11 b 7
i —j
FUSE #5
(10 AMP)
(5.3 AMP) ,.c 3 3
G50
V6 L5 F30
18WT
18DB 18BK 16RD
YL
I
WIPER TURN SIGNAL
J, i
CIGAR L I G H T E R
j ,
AUTOMATIC S H U T DOWN
WASHERS LAMPS SH 24 RELAY
SH 3 8 , 39 SH 34 RADIO SH 1 1 , 17
SH 45 F U E L PUMP
RADIO RELAY
ILLUMINATION SH 1 1 , 17
LAMPS POWERTRAIN
SH 45 CONTROL MODULE
SH 1 3 , 19
J938W-5 FUSE APPLICATION CHART YJ 2

20 6BK
ENGINE
GROUND
(RIGHT SIDE TO
REAR OF POWERTRAIN „
ENGINE) CONTROL V-K20
MODULE
C A V I T Y 20
( S E E SH 16)
3 5 / 7 5 AND 4 0 / 9 0 GENERATOR
( R I G H T S I D E FORWARD OF E N G I N E )
All
8BK
GY
( R I G H T REAR
TO AUTOMATIC TO IGNITION OF E N G I N E )
S H U T DOWN COIL
RELAY ( S E E SH 13)
( S E E SH 11)
All
8RD
BLACK RED
TO ENGINE
-AO 4 R D - S T A R T E R MOTOR
( S E E SH 7 )
BATTERY
AO 6 R D -
ENGINE BODY
GROUND GROUND
(RIGHT SIDE
(RIGHT S I D E
REAR OF
DASH P A N E L )
ENGINE)
YJ 3 CHARGING SYSTEM 2.5 L ENGINE J938W-5

WIRING DIAGRAMS 8W - S i
TO HORN R E L A Y t
FUSE # F 1 5
( S E E SH 33) J ( 1 0 AMP)
A4 18BK/R0
FUSE # F 1 6
( 1 0 AMP)
TO
HAZARD F L A S H E R f -
( S E E SH 3 4 )
TO<MÎ|SPLICE
(SEE SH 8) TO
HEADLAMP
SWITCH
TO I G N I T I O N „ L9 ( S E E SH 29)
SWITCH f- 18BK
( S E E SH 9) J
WT
TO \ M / SPLICE
(SEE SH 30)
TO ENGINE f
STARTER RELAY y
A6 ( S E E SH 7 ) A3
Al
12RD 12RD
12RD
BK OR
G4
D4 E4
•<f-
omo
•All 8RD
TO F U E L
PUMP AND
AUTOMATIC S H U T A6 L9 A3 A4
DOWN R E L A Y 12RD 18BK 12RD 18BK
( S E E S H 11) BK WT OR RD
All Al All
10RD 12RD 10RD
A14
16RD
WT
30A*3 50Ap 50A3 40A3 20Ap 50Ap 30A3 20Ap
-AO 6 R D — mmJmamaJLmmJLmmm\wm\mnmmmu\\mmmJhmmMm
Fl F2 F3 F4 F5
POWER D I S T R I B U T I O N C E N T E R
(SEE SH 6 7 )
F6 F7 F8
F9
F10 c
J938W-5 CHARGING SYSTEM 2.5L ENGINE YJ 4
ZO 6BK
ENGINE (RIGHT SIDE

GROUND REAR OF E N G I N E )
TO P O W E R T R A I N „
CONTROL MODULE V— K20 18DG
C A V I T Y 20
( S E E SH 22)
3 5 / 7 5 AND 4 0 / 9 0 GENERATOR
( R I G H T S I D E FORWARD OF E N G I N E )
All
8BK
GY
( R I G H T REAR
TO AUTOMATIC IGNITION OF E N G I N E )
S H U T DOWN COIL
RELAY ( S E E S H 19)
( S E E S H 17)
All
8RD
TO H E A T E D
TO^H^SPLICE OXYGEN SENSOR
( S E E SH 17)
(SEE SH 20)
BLACK RED
, TO ENGINE
-AO 4 R D - S T A R T E R MOTOR
( S E E SH 7)
ZO
4BK
BATTERY
•AO 6 R D -
BODY
ENGINE GROUND
GROUND (RIGHT SIDE
(RIGHT SIDE PaSELI
ENGINE)
YJ 5 CHARGING SYSTEM 4.0L ENGINE J938W-5

TO HORN R E L A Y < FUSE#F15

( S E E SH 33) J ( 1 0 AMP)
A4 18BK/RD
FUSE # F 1 6
( 1 0 AMP)
TO
HAZARD F L A S H E R V-
( S E E SH 3 4 )
TO<m^T]SPLICE
TO ABS
(SEE SH 8 ) TO POWER AND
HEADLAMP PUMP R E L A Y S
SWITCH ( S E E SH 57)
TO IGNITION „ L9 ( S E E SH 29)
SWITCH f 18BK r
( S E E SH 9) >
WT
TO< A6^> S P L I C E
s
(SEE SH 30)
TO ENGINE ,
S T A R T E R R E L A Y r-
A6 ( S E E SH 7) A3
Al
12RD 12RD
12RD
BK OR
G4
D4 E4
•All 8RD
TO F U E L
PUMP AND
AUTO SHUTDOWN
RELAY
( S E E SH 17)
A6 L9 A3 A4 AlO A20
All All
12RD 18BK 12RD 18BK 12RD HRD
10RD 10RD
BK WT OR RD BR DB
AM Al
16RD 12RD
WT
30A3 50A
40A
F9
•AO 6 R D -
Fl
i 1 1 1 1 1 1
F2 F3 F4 F5 F6 F7 F8
POWER D I S T R I B U T I O N CENTER F10
(SEE SH 67)
J938H-5
CHARGING SYSTEM 4.OL ENGINE YJ 6
8W - 18 W I R I N G DIAGRAMS J
TO IGNITION
TO POWER A41 18YL—( SWITCH
DISTRIBUTION ( S E E SH 9)
CENTER F 4 G5
( S E E SH 4 , 6 ) -T41 18BR/YL
4.0L ENGINE
^ T O <(G5> S P L I C E f
(SEE SH 10)
2.5L ENGINE G5
18DB
YL
i
I
I C6
ENGINE
A/C R E L A Y .-J\
S T A R T E R RELAY 5—G5 18DB/YL
S E E SH 49
( I N POWER
DISTRIBUTION
CENTER) T41 G5
( S E E SH 6 8 ) 18BR 18DB
YL YL
i
I ENG-1
!
! 9~~
— 2 . 5 L ENGINE
T41 18BR/YL »- •T41 18BR/YL
T40 HENG-lHo G5
14BR
18DB
YL
ENG
TO (PCM) LI 18VT
CAVITY 30
( S E E SH 2 2 ) BLACK
LI
18VT ( R I G H T REAR
OF ENGINE)
HENG-1 1
TO B A T T E R Y ( + ) TO BACK-UP LAMPS
(SEE.SH 3,5) ( S E E SH 5 1 , 5 2 )
G5
LI ,oG 18DB 18BR 18DB
T
18VT I WT YL YL
- C ^ A
PARK/NEUTRAL
POSITION BACK-UP
(SWITCH) LAMP S W I T C H
( L E F T S I D E OF ( L E F T S I D E OF
TRANSMISSION) TRANSMISSION)
LI 18VT-- -<f
LI 18VT
T41 18BR/YL*| LI 18VT-^®^
U
G5 18DB/WT*
— ENGINE S T A R T E R MOTOR ~ G5 18DB/WT*-^-^ n
( R E A R OF E N G I N E )
AUTOMATIC
TRANSMISSION MANUAL
TRANSMISSION
YJ 7 ENGINE STARTER SYSTEM J938W-5
-T41 18BR/YL--
TO A/C
COMPRESSOR
TO POWER CLUTCH
DISTRIBUTION TO^ZÎSPLICE RELAY
CENTER ( 4 . 0 L ENGINE)
( S E E SH 4 , 6 ) (SEE SH 31) ( S E E SH 4 9 )
-A4 18BK/RD
TO ABS DATA „
L I N K CONNECTOR V , /-2.5L
( 4 . 0 L ENGINE) \ / ENGINE
( S E E SH 5 7 )
Zl
TO < Z 1 2 > S P L I C E 18BK
(SEE SH 57)
MERCURY
SWITCH
UNDERHOOD L I G H T
( C E N T E R OF
HOOD INNER P A N E L ) BLACK
4 WHEEL
•Gl 18DG/GY DRIVE
SWITCH
( L E F T OF
BATTERY
(zGCD Zl 18BK
ON DASH
PANEL)
i , jf
TO 4WD ,
INDICATOR L I G H T ) Gl 18DG/GY •Gl 18DG/GY
( S E E SH 4 3 )
( L E F T OF
S T E E R I N G COLUMN)
4WD COMMAND TRAC SWITCH

J938W-5 UNDERHOOD LIGHT YJ 8
TO ENGINE
TO POWER
IGNITION STARTER
_r D I S T R I B U T I O N
- A l 12RD- SWITCH SYSTEM
3 CENTER F U S E F4
BLACK- (ON S T E E R I N G COLUMN) ( S E E SH 7 )
( S E E SH 4 , 6 )
( L E F T OF
14BK/0R
TO BRAKE LAMP
IN C L U S T E R
( S E E SH 4 1
A31 14BK/WT
A21 14DB
GROUND T H R U
<—Gl 1 S T E E R I N G COLUMN
ATTACHMENT
* - + - + | BRAKE
WARNING G i l 18WT/BK
SWITCH G i l 20WT/BK
( L E F T FRONT A22 1 4 B K / 0 R
FENDER
PANEL) 16 Al 12RD
A31 14BK/WT
• • • • • • • •
BLACK A41 18YL •A21 14DB
(BODY CONNECTOR
LEFT SIDE)
gannaana
16
•Gil 18WT/BK
PARK BRAKE S W I T C H
(ON PARK B R A K E )
YJ 9 IGNITION SWITCH J938W-5

FUSE #1
( 2 0 AMP) TO REAR
WIPER SYSTEM
A22 MBK/OR -V23 16BR/PK 4 (PARK S W I T C H )
^ ( H A R D TOP ONLY)
( S E E SH 3 7 )
, TO H E A T E R
CI 14DG • 4 BLOWER MOTOR
( S E E SH 4 7 )
TO F U S E F 1 3 ,
(ABS S Y S T E M ) V - •A22 MBK/OR TO A I R
( S E E SH 58) CI MDG • 4 CONDITIONING
SYSTEM
FUSE # 1 ( S E E SH 4 8 , 5 0 )
( 3 0 AMP]
-A31 14BK/WT - F 3 0 16RD -^TO<^>SPLICE
(SEE SH 2 4 )
FUSE # 4
( 1 5 AMP) L5
18BK
A31
MBK
WT*
TO TURN SIGNAL
C I R C U I T BREAKER
FLASHER
#11
( S E E SH 3 4 )
( 5 . 3 AMP)
TO
V6 18DB 4 WIPER SWITCH
M S E E SH 3 8 . 3 9 )
TO
V6 18DB- 4 W I P E R MOTOR
^ ( S E E SH 3 8 , 3 9 )
^ TO B U Z Z E R
•A21 1 4 D B - f q G5 1 8 D B / W T
7< FUSE #9
4 MODULE
( S E E SH 3 6 )
FUSE #5
( 1 5 AMP) TO D A Y T I M E
10 AMP)
RUNNING
1
A21 MDB— G5 1 8 D B / W T - n r G5 1 8 D B / W T -4 LAMPS MODULE
(CANADA ONLY)
( S E E SH 2 8 )
G50
18WT
YL
05
G50
18WT
YL
TO TO TO TO TO TO A/C
TO HEATED GAUGE CLUSTER GAUGE INDICATOR COMPRESSOR
REAR PACKAGE CAVITY 19 PACKAGE LAMPS CLUTCH R E L A Y
<G5Q> WINDOW CAVITY 2 ( S E E SH 4 1 ) CAVITY 12 CAVITY 3 ( S E E SH 4 9 )
RELAY ( S E E SH 4 3 ) ( S E E SH 4 3 ) ( S E E SH 4 1 ) AND B A C K - U P
(HARD T O P ) LAMP S W I T C H
SPLICE
( S E E SH 5 4 ) ( S E E SH 7 )
(SEE S H 1 3 , 19)
J938W-5 IGNITION SWITCH YJ 10

TO
<G50)
TO POWER S T E E R I N G
SPLICE
P R E S S U R E SWITCH
( S E E SH 13)
( S E E SH 14)
L
G50 18WT/YL
TO F U E L TANK
TD
SENDING U N I T
DATA L I N K
( S E E SH 55)
CONNECTOR
A141
( S E E SH 13) 16DG F U E L PUMP R E L A Y
BK ( I N POWER
DISTRIBUTION A14 K51
CENTER) 16RD 18DB
TO F U E L PUMP ( S E E SH 6 8 ) WT YL
( S E E SH 5 5 )
G50 18WT/YL
TO
POWER
O) DISTRIBUTION
CENTER-
ENGINE A142 AUTOMATIC FUSE F l
GROUND 18DG S H U T DOWN R E L A Y
A142 A14 ( S E E SH 3)
OR ( I N POWER
(RIGHT S I D E 18DG 16RD
OR DISTRIBUTION WT
REAR OF
CENTER)
ENGINE)
( S E E SH 6 8 )
TO <A142> S P L I C E TO<AH2>T|SPLICE
(SEE SH 14) h (SEE SH 3)
A142
18DG
OR TO <K4 SPLICE
V 3 10
( S E E SH 15)
ENG-2 — y s. — ENG-2
•K4 18BK/LB y
HEATED
OXYGEN SENSOR
A14 K51
(ON EXHAUST 16RD 18DB
PIPE) WT YL
11 12 41 3 51
GROUND GROUND HEATED BATTERY RELAY|
OXYGEN COIL
SENSOR POWERTRAIN CONTROL MODULE (PCM) CONNECTOR
(UNDER BULKHEAD CONNECTOR IN ENGINE COMPARTMENT) ( S E E SH 6 3 )
. FUEL INJECTION
YJ 11 I G N I T I O N S Y S T E M 2. 5 L E N G I N E J938w-s
CAMSHAFT P O S I T I O N
SENSOR ( S T A T O R )
TO OAYTIME
(IN DISTRIBUTOR)
VEHICLE SPEED RUNNING LAMP
SENSOR MODULE
(ON REAR OF ( S E E SH 28)
TRANSMISSION)
67
20WT
OR
K7 I80R
i n
CRANKSHAFT
POSTION
CI
SENSOR
K7
180R 11
K44 K4 ^HENG-lh K 4 67 67
18TN 18BK 18BK 18WT 20WT
YL LB LB OR OR
B4
(LEFT SIDE HENG-1 h

B E L L HOUSING)
67
K7 180R 67 20WT
18WT OR
OR
14
-| ENG-2-
G7 G7
20WT 20WT
OR OR
K4
18BK
LB
K4
18BK
LB 1
TO C L U S T E R
SPEEDOMETER
( S E E SH 41)
K24 TO SPLICE
186Y 18TN
180R
B K
( S E E SH 15) YL
24 44 7 47
SENSOR CMP SENSOR VEHICLE
MAGH MAG(+) SPEED SIGNAL
POWERTRAIN CONTROL MODULE (PCM) CONNECTOR
(UNDER B L K H E A D CONNECTOR I N ENGINE COMPARTMENT) ( S E E SH 6 3 )
FUEL INJECTION
J938W-5 IGNITION SYSTEM 2.5L ENGINE YJ 12
TO IGNITION IGNITION
SWITCH COIL
( S E E S H 10) ( R I G H T S I D E REAR
OF ENGINE*
12 A21 H O B -
FUSE # 5
( 1 0 AMP)
G50 18WT/YL
AH2 18DG/0R —Kiifji
D5
x
TO
(AH2>1|
G50
18WT , SPLICE
YL ( S E E SH 3)
TO F U E L ,
PUMP R E L A Y V — G 5 0 1 8 W T / Y L
( S E E S H 11)
TO TO C L U S T E R
AUTOMATIC UP S H I F T
SHUT DOWN C—GSO LAMP
RELAY ( S E E SH 4 1 )
DATA L I N K (SEE SH 11
CONNECTOR
( L E F T REAR ENGINE
COMPARTMENT)
mm
Zli
16BK
WT
TO
:zr57i R19
18GY
SPLICE
( S E E SH 1
K54
200R
BK
.A* X
T 19
5 25 45 9 54
GROUND DATA L I N K DATA L I N K B+ UPSHIFT IGNITION
(DATA 2 ) (DATA i ) LAMP
P O W E R T R A I N CONTROL MODULE (PCM) CONNECTOR j
(UNDER BULKHEAD CONNECTOR I N E N G I N E COMPARTMENT) ( S E E S H 63)1
FUEL INJECTION
YJ 13 IGNITION SYSTEM 2.5L ENGINE J938W-5
POWER
STEERING Zl 18BK
SWITCH
(NEAR POWER KIO 18DB/0R
S T E E R I N G PUMP)
TO
Zl 18BK- -<f KIO 18DB/0R
SPLICE
( S E E SH 11)
Kll 18WT/DB
K12 18TN
TO AUTO
K13 1 8 Y L / W T
S H U T DOWN r_
K14 18LB/BR A B FUEL RELAY r
/ INJECTORS ( S E E SH 11)
( L H ENGINE IDLE AIR
BANK) CONTROL
MOTOR
A142 18DG/0R (ON T H R O T T L E
BODY)
/ // l \ / \
/ / I \
/ l \
j£Lh .r^h, l r r
^ ~ ] l .rî,
niinfi
I— A142 18DG/0R
A142 18DG/0R
A142 18DG/0R
A142 18DG/0R
A142 18DG/0R
Kll K13 K14

K12 18YL 18LB
18WT
18TN WT BR
OB
X i
J L J L J L
16 15 14 13 57 10 59 40 60 39
INJ INJ INJ INJ SENSE P/S IAC IAC IAC IAC
SWITCH

(UNDER BULKHEAD CONNECTOR IN ENGINE COMPARTMENT) ( S E E SH 6 3 )
FUEL INJECTION
TO CRANKSHAFT
P O S I T I O N SENSOR
( S E E SH 12)
TO <k^T] SPLICE TO OXYGEN SENSOR

K4 18BK/LB ( S E E SH 11)
(SEE SH 12) ^
ENGINE
COOLANT
MAP SENSOR TEMPERATURE
(REAR CENTER SENSOR
OF ENGINE COMP.) (BEHIND LH
ENGINE MOUNT)
INTAKE AIR
TEMPERATURE
THROTTLE SENSOR
P O S I T I O N (SENSOR) (ON I N T A K E
(ON T H R O T T L E BODY) NEAR T H R O T T L E
BODY)
C B A
teg Is
'— K4 18BK/LB K4 18BK/LB
K4 18BK/LB
6 1 4 2 21
SENSOR MAP GROUND ECT INTAKE
RETURN SENSOR SENSOR A I R TEMP
(+) SENSOR
CONNECTOR
(UNDER BULKHEAD CONNECTOR I N ENGINE COMPARTMENT)
( S E E SH 6 3 )
. FUEL INJECTION
YJ 15 IGNITION SYSTEM 2.5L ENGINE Jssau-s
TO C L U S T E R
TACHOMETER
( S E E SH 4 1 )
TO BRAKE
SWITCH TO C L U S T E R TO C L U S T E R
( S E E SH 3 4 ] MALFUNCTION INDICATOR S E R V I C E REMINDER
LAMP INDICATOR LAMP
nnn, ( S E E SH 4 1 ) ( S E E SH 4 1 )
m m
V40 G3 G21 G24

18WT 20BK 20GY 20GY
PK PK LB PK
C5 H6 C4
[HI
TO
GENERATOR
( S E E SH 3 ) V40 G3 G21 G24
18WT 20BK 20GY 20GY
PK PK LB PK
12 13
HENG-2 ENG-2 h~ HENG-2 HENG-2
V40 G3 G21 G24

K20 18WT 20BK 20GY 20GY
18DG PK PK LB PK
i
JL
20
GENERATOR
FIELD
i
29
TCC
FEED
i 32
MIL
i 43
TACH
SIGNAL
± 56
SRI
P O W E R T R A I N CONTROL MODULE (PCM) CONNECTOR

(UNDER BULKHEAD CONNECTOR I N ENGINE COMPARTMENT) ( S E E SH 63)
FUEL INJECTION
4 WIRING DIAGRAMS 8W - 79
CAMSHAFT P O S I T I O N TO DAYTIME
SENSOR ( S T A T O R ) VEHICLE SPEED RUNNING LAMP
(IN DISTRIBUTOR) SENSOR MODULE
(ON REAR OF ( S E E SH 28)
TRANSMISSION)
CRANKSHAFT
POSTION
SENSOR
K4 G7
K7
18BK 18WT
K44 K4 180R
K7 LB OR
18TN 18BK
180R
YL LB B4
(LEFT SIDE
B E L L HOUSING)
ENG-2h
K4 K4
18BK 18BK
LB LB
TO C L U S T E R
SPEEDOMETER
( S E E SH 4 1 )
L
K44 G7
SY T 0
< ^ > S P L I C E K7
18TN 18WT
180R
BK ( S E E SH 2 1 ) YL OR
24 44 7 47
SENSOR CMP SENSOR VEHICLE
MAGH MAG(+) S P E E D SIGNAL
(UNDER BULKHEAD CONNECTOR I N ENGINE COMPARTMENT) 1 SEE S H 6 4
FUEL INJECTION
J938W-5 IGNITION SYSTEM 4 . OL ENGINE YJ 18
BW - 80 WIRING DIAGRAMS 4
IGNITION
COIL
(ON ENGINE
RIGHT S I D E
FUSE # 5
LOWER)
( 1 0 AMP)
TO IGNITION.
SWITCH y •A21 14DB-
( S E E SH 10)
G50
18WT
YL
A142
18DG
TO F U E L ,
PUMP R E L A Y y G50 18WT/YL
( S E E SH 17) T0<M42>1 [SPLICE
(SEE SH 5 )
TO
TO C L U S T E R
AUTOMATIC
UP S H I F T LAMP
S H U T DOWN \ - -G50 18WT/YL
( S E E SH 4 1 )
RELAY
( S E E SH 17)
K54
200R
BK
( L E F T REAR ENGINE
COMPARTMENT)
DATA L I N K FG1B
CONNECTOR
3lf5| G50 18WT/YL

K54
G50 18WT/YL 200R
Zll BK
16BK
WT
11
ENG 2 h
TO < Z 1 > 7 SPLICE

l G50 K54
D20 ( S E E SH 17) H BK
D21
18WT 200R
K19
20LG 20PK 18GY
WT YL BK
45 5 25 9 54 19
DATA L I N K GROUND , D
KA T A L I N
B + UPSHIFT IGNITION
(DATA 1) (DATA 2 ) LAMP
(UNDER BULKHEAD CONNECTOR I N ENGINE COMPARTMENT) ( S E E SH 6 4 )
FUEL INJECTION
YJ 19 IGNITION SYSTEM 4. OL ENGINE USBBW-S
Kll 18WT/DB IDLE AIR

K12 18TN CONTROL
MOTOR
K13 18YL/WT (ON T H R O T T L E
CO
K14 18LB/BR A FUEL BODY)
K15 18PK/BK INJECTORS
( L H ENGINE
K16 18LG/BK BANK)
A142 18DG/0R TO <A142>1| S P L I C E
(SEE S H 5)
/ / / \ \ \
/ / / \ \ \
/ / \ \
/ / / \ \ \
/ / / \ \ \
/ / / \ \ \
\
\
£±X r£ih £ h XÛ XÛ
fl fiinfiini
-A142 18DG/0R-
•A142 18DG/0R-
-A142 18DG/0R
-A142 18DG/0R-
-A142 18DG/0R-
K40 K39
18BR 18GY
WT RD
Kll K13 K14 K15 K1G K59 K60

K12
18WT 18YL 18LB 18PK 18LG 18VT 18YL
18TN
DB WT BR BK BK BK BK
16 15 14 13 38 58 57 59 40 60 39
INJ INJ INJ INJ INJ INJ BATTERY IAC IAC IAC IAC
1 2 3 4 5 6 SENSE
(UNDER BULKHEAD CONNECTOR IN ENGINE COMPARTMENT) ( S E E SH 64)
FUEL INJECTION
J938W-5 IGNITION SYSTEM 4.OL ENGINE YJ 20
THROTTLE
P O S I T I O N (SENSOR)
(ON T H R O T T L E BODY) TO CRANKSHAFT
P O S I T I O N SENSOR
( S E E SH 18) AIR
TEMPERATURE
SENSOR
(ON INTAKE
NEAR T H R O T T L E
BODY)
TO OXYGEN ,
SENSOR y
( S E E SH 17)
ENGINE
COOLANT
TEMPERATURE
MAP SENSOR SENSOR
(REAR CENTER (BEHIND LH
OF ENGINE COMP. ENGINE MOUNT)
K4 K4
18BK 18BK
LB LB
K4
18BK
LB
C B A
fOQcfl K4 18BK/LB
-K4 18BK/LB
K6
20VT
WT
K22 K6 Kl K4 K21
180R 20VT 20DG 18BK 18BK
DB WT RD LB RD
22 6 1 4 2 21
TP(S) SENSOR MAP GROUND ECT INTAKE
RETURN SENSOR SENSOR A I R TEMP
(+) SENSOR
(UNDER BULKHEAD CONNECTOR IN E N G I N E COMPARTMENT) ( S E E SH 6 4 )
FUEL INJECTION
YJ 21 IGNITION SYSTEM 4.OL ENGINE J938W-5
TO BRAKE
SWITCH TO C L U S T E R
( S E E SH 3 4 ) TO C L U S T E R
TO TO E N G I N E TO C L U S T E R S E R V I C E REMINDER
MALFUNCTION
GENERATOR STARTER RELAY I N D I C A T O R LAMP TACHOMETER INDICATOR LAMP
( S E E SH 5 ) ( S E E SH 7 ) ( S E E SH 41) ( S E E SH 4 1 ) ( S E E SH 4 1 )
DTJU
V40 63 G21 624

18WT 20BK 20GY 20GY
PK PK LB PK
C4
V40 T41 G3 G21 G24

18WT 18BR 20BK 20GY 20GY
PK YL PK LB PK
8 12 13
HENG-2 ENG-2h HENG-2h HENG-2h HENG-2h
V40 T41 G3 621 G24

K20
18WT 18BR 20BK 20GY 20GY
18DG
PK YL PK LB PK
20 29 30 32 43 56
GENERATOR TCC PARK/NEUTRAL MIL TACH SRI
FIELD FEED POSITION(SWITCH) SIGNAL LAMP

(UNDER BULKHEAD CONNECTOR I N E N G I N E CONPARTMENT) ( S E E SH 64)
FUEL INJECTION
J938W-5 IGNITION SYSTEM 4.OL ENGINE YJ 22
TO GAUGE PACKAGE TO GAUGE PACKAGE

ENGINE O I L ENGINE COOLANT
P R E S S U R E GAUGE T E M P E R A T U R E GAUGE
( S E E SH 43) ( S E E SH 43)
G60 G20
18GY 18VT
YL YL
QQQQQ
BLACK
7A ( L E F T S I D E OF
G
(QQl1QQ' 1 U
G60 G20
18GY 18VT
YL YL
HENG-lh HENG-2h
15
GBO
18GY
YL
ENGINE
COOLANT
TEMPERATURE
SENDING
1 0 2 ENGINE O I L UNIT
PRESSURE ( F R O N T OF
SENDING U N I T ENGINE)
( R I G H T REAR
CORNER OF
CYLINDER
BLOCK)
ENGINE OIL PRESSURE

YJ 23 AND TEMPERATURE SYSTEM J938W-5
TO TO
IGNITION SWITCH RADIO R E L A Y
( S E E S H 10) ( S E E SH 45)
All
14BK F30
WT 18RD
F U S E #1
( 2 0 AMP)
TO RADIO
( S E E SH 4 5 )
F30 18RD
l
1i nn
F30 18RD \
'u u IGHTER
' ^ H
_^ TO < ^ > SPLICE y

-Zl 14BK- Zl 18BK
( S E E SH 3 2 )
so m
BO m -
BLACK (ABOVE A/C HOUSING)
TO BLOWER
mom - Zl 16BK Zl 16BK \
>
, MOTOR v
( S E E SH 50)
mom \
H
i. i
1 in n \ CIGAR
i• U L / LIGHTER
i
F30 16RD-
WITH AIR CONDITIONING
J938H-5 CIGAR LIGHTER YJ 24

El
L3 16RD/0R G34 18RD/GY

TO DIMMER -L3 16RD/0R •
SWITCH
( S E E SH 2 9 ) HI
L4 16VT/WT -L4 16VT/WT •
Q]A3
•L60 18TN- -<< L60 18TN-
TO T U R N / H A Z A R D
SWITCH ASSEMBLY
( S E E SH 3 4 ) C2
TO REAR WINDOW.
•L61 18LG- -« 1 WASHER PUMP S
I
L61 ( S E E SH 37)
18LG
L3 16RD/0R
L3 16RD/0R
L4 16VT/WT
LEFT
16VT/WT -
HEADLAMP
W L=r^
L60 18TN-
L E F T PARK
AND T U R N
S I G N A L LAMP
L7 18BK/YL
LEFT SIDE
MARKER
LAMP L7 18BK/YL
LEFT
FOG LAMP
(OPTIONAL)
L39 16LB
TO FRONT
(RADIATOR f — © J } WINDSHIELD
SUPPORT -J=r WASHER PUMP
TO L E F T — ( S E E SH 3 8 , 3 9 )
OF L E F T
HEADLAMP)
TO HORN
(SEE SH 33)
YJ 25 FRONT END LIGHTING J938W-5

E2
TO C L U S T E R
-G34 18RD/GY -G34 18RD/GY HIGH BEAM LAMP
( S E E SH 4 1 )
TO < L 7 > S P L I C E
( S E E SH 30)
T
L7
18BK
YL
IA1
L7
18BK
YL
f
13 16RD/0R •Zl 16BK-
Z^C
m
RIGHT
L4 16VT/WT• L4 16VT/WT -
HEADLAMP
-L3 16RD/0R
L60 18TN- •L60 18TN-

L60 18TN-
R I G H T PARK
Zl 18BK- AND T U R N
S I G N A L LAMP
L7 18BK/YL
L7
L7
18BK/YL
18BK/YL L7
L60 18TN
18BK/YL D RIGHT S I D E
MARKER
LAMP
L39 16LB
18BK-
18BK/WT• ID RIGHT
FOG LAMP
(OPTIONAL)
(RADIATOR
SUPPORT
— TO R I G H T
OF R I G H T
HEADLAMP)
TO FOG
L39 16LB- LAMP S W I T C H
( S E E SH 3 0 )
J938W-5 FRONT END LIGHTING YJ 26

5 L20 16LG/WT
E 1
TO DIMMER
E1
L3 16RD/0R
SWITCH
( S E E SH 2 9 ) 5 L3 16RD/0R «
!H1
•L4 16VT/WT
5— L4 16VT/WT
L3
16RD
OR
A3
L60 18TN- •L60 18TN-

TO T U R N / H A Z A R D
SWITCH ASSEMBLY
( S E E SH 3 4 )
L61 18LG-
Zl
18BK
C2
•L3 16RD/0R
L61
18LG
LEFT
•L4 16VT/WT
HEADLAMP
ofi
L60
•Zl 16BK 18TN
TO REAR
WINDOW „
•L61 18LG- WASHER S— Zl 1BBK
PUMP
L E F T PARK ( S E E SH 3 7 )
AND T U R N Zl 18BK-
S I G N A L LAMP
L7 18BK/YL
L61 18LG L7 18BK/YL•

LEFT S
MARKER
LAMP
L7 18BK/YL L7 18BK/YL
Zl
18BK
Z1 16BK
LEFT
FOG LAMP
-18BK/WT
*ms—
(OPTIONAL)
— 18BK — -L39 16LB- L39 16LB
Zl
16BK
, , TO FRONT
(RADIATOR r — @ 3 > •Zl 16BK- 4 WINDSHIELD
SUPPORT -zzLr WASHER PUMP
TO L E F T — ( S E E SH 3 8 , 3 9 )
OF L E F T
HEADLAMP)
TO HORN
(SEE SH 33)
YJ 27 FRONT END LIGHTING (CANADA) J938W-5

-L20 16LG/WT L20 16LG/WT • D A Y T I M E RUNNING

L I G H T MODULE
-L3 16RD/0R L3 16RD/0R-

o o
G34 18RD/GY• o o
-L3 16RD/0R 0 o
o o
—1
10
-L4 16VT/WT L4 16VT/WT -
65 G7
18DB 20WT ( E N G I N E COMPARTMENT
WT OR LEFT SIDE)
-Zl 18BK-
TO < L 7 > S P L I C E B2 CI
G7
( S E E SH 30) L4 G5 20WT
T
L7
16VT
WT
„ TO C L U S T E R
18DB
WT
, S \
OR
{
„ TO V E H I C L E
S P E E D SENSOR
( S E E SH 1 2 , 1 8 )
18BK '—( HIGH-BEAM LAMP '—( TO \ G 5 / S P L I C E
YL }
( S E E SH 4 1 ) , V
SEE SH 10
Al
Zl 16BK-
RIGHT
•L4 16VT/WT- L4 16VT/WT -
HEADLAMP
-L3 16RD/0R- 2^
•L60 18TN- -L60 18TN-
L60 18TN
R I G H T PARK
Zl 18BK AND T U R N
SIGNAL LAMP
L7 18BK/YL
-L7 18BK/YL L60 18TN

RIGHT S I D E
MARKER
-L7 18BK/YL L7 18BK/YL LAMP
18BK-
•L39 16LB RIGHT
FOG LAMP
(OPTIONAL)
18BK/WT-
dzr TO R I G H T
= OF R I G H T
HEADLAMP)
Di
GJ TO FOG
{ LAMP S W I T C H
-» L39 16LB-
> ( S E E SH 3 0 )
J938W-5 FRONT END LIGHTING (CANADA) YJ 28

8 W - SO WIRING DIAGRAMS
TO POWER D I S T R I B U T I O N
CENTER F U S E F7
( S E E SH 4 . 6 ) -A6 12RD/BK
A3
12RD F U S E 18
OR
(20 AMP)
E4
A3 F33
12RD 18PK
OR RD
-L7 18BK/YL
-L20 16LG/WT
HEADLAMP
SWITCH
F33 18PK/RD
L2 16L6 B H
A3 1 2 R D / 0 R
:B
L7 18BK/YL
Bl
L3 16RD/0R
L2 16LG i L20 16LG/WT -»—L20 16LG/WT
TO
L4 16VT/WT DIMMER D A Y T I M E RUNNING
L4 16VT/WT SWITCH LAMP MODULE
( O P E R A T E D BY ( S E E SH 2 7 )
TURN S I G N A L
L20 16LG/WT
LEVER)
L20 16LG/WT
L4 16VT/WT•
L3 16RD/0R
TO FRONT END
~ LIGHTING
L4 16VT/WT ( S E E SH 2 5 . 2 7 )
YJ 29 HEADLAMP SWITCH J938W-5

WIRING DIAGRAMS 8 W - 91
|G4 TO POWER
DISTRIBUTION
-A6 12RD/BK A6 12RD/BK A6 12RD/BK CENTER F U S E F 3
( S E E SH 4 . 6 )
TO H E A T E D REAR
WINDOW R E L A Y
A6 12RD/BK -F81 14BR- (HARD T O P )
( S E E SH 53)
FUSE # 6
( 2 5 AMP)
J O S T O P LAMP
-F32 18PK/DB i SWITCH
( S E E SH 34)
FUSE #3
( 1 5 AMP) F32
TO PANEL LAMP 18PK
OIMMER S W I T C H DB
( S E E SH 3 1 )
J .
TO B U Z Z E R
( S E E SH 3 6 )
L7 18BK/YL f TO T A I L LAMPS
L7 18BK/YL
> ( S E E SH 51)
L7 18BK/YL -<f L7 18BK/YL -^TO<L7K1 S P L I C E

(SEE SH 2 6 , 2 8 )
Al
TO RADIO
ILLUMINATION RELAY
( S E E SH 4 5 )
- L4 16VT/WT
-Zl 20BK
-L4 16VT/WT
FOG LAMP
SWITCH
(BELOW AND [ C H- L 3 9 16LB
TO T H E R I G H T
OF S T E E R I N G
COLUMN)
-Zl 20BK- - £ TO < Z ^ > S P L I C E
(SEE SH 3 2 )
Dl
f TO FOG LAMPS
L39 16LB- L39 16LB- ~> ( S E E SH 2 6 , 2 8 )
J938W-5 HEADLAMP SWITCH YJ 30

8W • 92 W I R I N G DIAGRAMS J
TO TO
-L7 18BK/YL
O
SPLICE
<8>
SPLICE
-M2 18YL
( S E E SH 3 0 ) ( S E E SH 35)
E2 200R-
L7 M2 L
E2 18TN|
18BK/YL 18YL L
Z1 18BK
-E2 200R-
E2 200R
h- TO RADIO
( S E E SH 45)
TO GAUGE
f- PACKAGE
( S E E SH 43)
, , TO C L U S T E R
«—( I L L U M . LAMPS
>
( S E E SH 41)
SPLICE
( S E E SH 8 )
TO S E A T B E L T /
KEY B U Z Z E R f
MODULE >
( S E E SH 3 6 ) TO W I N D S H I E L D
SPLICE TO W I N D S H I E L D
( W I T H HARD T O P ) W I P E R MOTOR
( S E E SH 54) ( S E E SH 3 8 , 4 0 )
TO REAR
LIGHTING
( W I T H SOFT TOP)
( S E E SH 51)
YJ 31 PANEL LAMPS DIMMER SWITCH U938W-5

T R A N S M I S S I O N RANGE
STRG ILLUMINATION
COLUMN
-E2 200R- -18GY-
-E2 200R
-E2 200R
TO GAUGE
, PACKAGE > .
Z 1 1 8 B K
( S E E SH 4 3 ) C
TO REAR W I P E R
7 SWITCH
TO S T O P L A M P . C
(HARD T O P )
SWITCH h -Zl 18BK
S E E SH 3 7 )
( S E E SH 34)
7 TO RADIO R E L A Y
TO BLOWER X I c
( S E E SH 4 5 )
MOTOR tr 11
HBK
( S E E SH 4 7 )
J938W-5 PANEL LAMPS YJ 32

FUSE # F 1 5
TO POWER
(10 AMP)
DISTRIBUTION CENTER F31 18VT I
FUSE F8
(SEE SH 4,6)
•F31 18VT
T A4 18BK/RD
|F15
F16
HORN RELAY
(IN POWER
DISTRIBUTION
CENTER)
(SEE SH 68)
A-BLACK
-X3 18BK/RD CDC©

/ V-TL
02 CD -X3 18BK/RD
£3 CD
dacf
STRG
COLUMN dCZ) <n cd
GUCD CD CD
18BK
(LEFT OF STEERING COLUMN)
HORN BRUSH/ G6
S L I P RING
(IN CENTER OF
STEERING WHEEL)
(LEFT FRONT INNER FENDER) X2

18BK # m 18DG
RD
HORN *
SWITCH
STEERING G3
COLUMN
GROUND
(THROUGH CENTER
SHAFT)
X2 18DG/RD
TO SPLICE
[SEE SH 25,27)
YJ 33 HORN J938W-5
IGNITION SWITCH TO PCM

( S E E S H 10) CAVITY 2 9
( S E E SH 1 6 . 2 2 K
V40
18WT
PK
TURN
SIGNAL
FLASHER
(ON F U S E
PANEL)
18WT
STOP LAMP SWITCH
L60 18TN -i SUPPORT BRACKET)
TO C L U S T E R
R I G H T T U R N SIGNAL
LAMP
( S E E S H 41)
TO L E F T TORIGHT
REAR REAR
STOP/TURN STOP/TURN TO R I G H T
TO L E F T
LAMP LAMP FRONT
FRONT
PARK/TURN (SEE SH 5 1 ) (SEE SH 5 1 ) PARK/TURN
LAMP LAMP
( S E E SH 2 5 . 2 7 ) (SEE SH 2 5 . 2 7 )
U938W-5 STOP/TURN AND HAZARD FLASHER SYSTEMS YJ 34

TO POWER D I S T R I B U T I O N
CENTER-FUSE F8
( S E E SH 4 , 6 )
T. -A4 18BK/RD
TO RADIO
( S E E SH 45)
Ml 1 8 P K -
Ml 1 8 P K -
M2 1 8 Y L
TO K E Y - I N
SWITCH
S E E SH 3 6 )
TO PANEL LAMP
DIMMER S W I T C H
( S E E SH 3 1 )
G16 18BK/LB
BLACK
• • • • • • • •
(BEHIND
BLACK 16 RIGHT
IR~Jfc=3TF
16
>u BLACK
ABOVE PARKING
BRAKE HANDLE)
COURTESY
LAMP)
(BELOW Ml
LEFT BLACK 18PK
SPEAKER) M2
18YL
(•CD <£\n>
G16
18BK
M2
18YL
M2 1 8 Y L
-Ml 20PK-
(ABOVE
L E F T REAR
^ C D
pGDD
da
CD
Do)
( n o t
dG CD
<£]CD
v3
RIGHT
COURTESY
LAMP
LB T A I L LAMP) TZI—czr
M2
18YL
LEFT
-Ml 18PK-
COURTESY
LAMP
as mo
L E F T FRONT
DOOR JAM
SWITCH
s DOME
LAMP
(HARD TOP
ONLY)
R I G H T FRONT
DOOR JAM
SWITCH
YJ 35 DOME AND COURTESY LAMPS J938W-3

J
SPLICE TO IGNITION
SWITCH
(SEE SH 30) ( S E E SH 10)
TO
FUSE # 9
( 1 5 AMP)
SPLICE
( S E E SH 10)
TO
65 18DB/WT
TO C L U S T E R SPLICE
TO S T O P LAMP ( S E E SH 31)
S E A T B E L T WARNING
SWITCH
LAMP
( S E E SH 3 4 )
( S E E SH 41)
Zl 20BK
STRG
COLUMN
Z l 14BK
G10 18LG/RD
IGNITION BODY HARNESS

CONNECTOR
KEY
16
WARNING
SWITCH
(IN aaaaoaoo
COLUMN)
BLACK
• • • • • • • •
• • • • • • • •
16
18PK / B U Z Z E R MODULE (ABOVE PARKING
/ ( P L U G S INTO F U S E P A N E L ) BRAKE HANDLE)
Z l 14BK-
F32 18PK/DB —i <—G26 1 8 L B

STRG
COLUMN
Zl 18BK
P • • • .
IcOj cD=t c£L cQj!
BLACK
G10
18LG/RD 3 1
G5 18DB/RD
Zl 20BK- —G13 20DB/RD

(SEE SH 54) SEAT B E L T
G16 SWITCH
18BK ( I N SEAT
LB BELT
r —-Zl 18BK
BUCKLE)
TO REAR L I G H T I N G
(SEE SH 51) j
ii
. TO L E F T FRONT DOOR ( S O F T TOP ONLY) NC
JAMB S W I T C H
(SEE SH 35)
1
S E A T B E L T / I G N I T I O N KEY
J938H-5 WARNING B U Z Z E R YJ 36
TO
IGNITION J53L BLACK
SWITCH
FUSE #1 V22 1 6 B R / Y L — { P ) [ A } - V20 18BR/WT
(SEE SH 10)
( 2 0 AMP)
[§}- V13 18BR/LG
Zl 18BK-~fc1fo|
j [
—V23
E: — 16BR/L6
Z l 12BK
j [ —V23 16BR/PK
REAR WIPER MOTOR
YJ 37 REAR WIPER/WASHER SYSTEM J93BH-S

U1PPD ~
i
s~>^^~~^ WASHER »
jf H I HI ^ ALSO MOVES
5 WIPER SWITCH
vSWITCH
S
/
/
<
TO IGNITION 1
SWITCH OFF f • • OFF < L J ° S L J OFF/ • ION
1
( S E E SH 10) LO 1
YL GY VT WT WIPER/WASHER PK
SWITCH
W/WIPER
CIRCUIT
BREAKER
(5.3 AMP) (UNDER I N S T R U M E N T
PANEL N E X T TO
GRAY STEERING
M COLUMN)
n
V6 18DB-
V6 180B
V10 18BR Zl
1BBK
•V4 18RD/YL
V3 18BR/WT TO
* F3|
SPLICE
(SEE SH 31)
V5 180G/YL-
•ODD Zl 18BK
V10
18BR
BLACK
I E
^ 1
A H Jo
1
BL GY BK WT RD
WIPER
MOTOR
PARK (LOWER L E F T
WASHER SWITCH CORNER OF
PUMP WINDSHIELD
WIPERS WIPERS HOUSING)
(ON F L U I D
UP DOWN
RESIVOR)
SPLICE
( S E E S H 25.27)
J938W-5 WINDSHIELD WIPER SYSTEM YJ 38

TO IGNITION
SWITCH
( S E E S H 10)
W/WIPER
CIRCUIT
BREAKER
( 5 . 3 AMP)
V6 18DB
V6 18DB
V 1 0 18BR V10 18BR
V4 18RD/YL
V3 18BR/WT
F3
V10 V5 18DG/YL
18BR UUE3Q
- Z l 18BK —
H
H,
am
am
BL GY BK WT RD
WASHER
PUMP WIPER
TO PARK MOTOR
(ON F L U I D
(LOWER L E F T
RESIVOR)
SWITCH
WIPERS
V I WIPERS
CORNER OF
WINDSHIELD
SPLICE HOUSING)
( S E E SH 2 5 , 2 7 ) UP DOWN
YJ 39 INTERMITTENT WIPER SYSTEM J938W-5

J
WIPER/WASHER SWITCH
MIST MIST / HI MIST /

• HI
L
% 1 #HI
DELAY f
OFF < I LO OFF • • LO
OFF OFF • • ON
WASH
DELAY SWITCH
YL GY DG r— V T — ' BR WT PK
ABC D E F G
(UNDER
INSTRUMENT
INTERMITTENT PANEL NEXT
WIPER TO S T E E R I N G
MODULE COLUMN)
(UNDER I N S T R U M E N T
PANEL NEXT TO
STEERING
COLUMN)
TO
<§Eg
SPLICE
( S E E SH 3 1 )
J938W-5 INTERMITTENT WIPER SYSTEM YJ 40

J
TACHOMETER SIGNAL
G21 2 0 G Y / L B
BRAKE WARNING LAMP ( S E E SH 1 6 . 2 2 )
69 1 8 G Y / B K _
( S E E SH 9 )
SPEEDOMETER S I 6 N A L
G7 2 0 W T / 0 R
MALFUNCTION ( S E E SH 1 2 . 1 8 )
INDICATOR LAMP
G3 2 0 B K / P K
TO
( S E E SH 1 6 . 2 2 )
Zl 18BK-
GROUND S P L I C E
( S E E SH 3 2 )
IGNITION FEED
65 1 8 D B / W T
( S E E SH 10)
11
S E R V I C E REMINDER
INDICATOR LAMP
G24 2 0 6 Y / P K S E A T B E L T WARNING LAMP
( S E E SH 1 6 . 2 2 ) 613 20DB/RD
( S E E SH 3 6 )
H I 6 H BEAM INDICATOR
10 634 18RD/GY
21
UP S H I F T LAMP ( S E E SH 2 6 . 2 8 )
K54 2 0 0 R / B K
( S E E SH 1 3 . 1 9 )
L E F T TURN S I 6 N A L LAMP
L 6 1 18LG
( S E E SH 3 4 )
A N T I - L O C K LAMP
619 1 8 L 6 / 0 R
( S E E SH 58)
IGNITION FEED
65 1 8 D B / W T
( S E E SH 10)
RIGHT TURN
SIGNAL LAMP
L 6 0 18TN
( S E E SH 3 4 ) TO
Zl 18BK
GROUND S P L I C E
( S E E SH 3 2 )
ILLUMINATION LAMPS T0<E2

E2 200R
SPLICE
( S E E SH 31)
YJ 41 CLUSTER CONNECTOR J938W-5

W I R I N G DIAGRAMS 8 W - 103
SP P U L S E
13 o-
ELECTRONIC
SPEEDOMETER
LOGIC GROUND
14 o-
TA P U L S E
12 o-
ELECTRONIC
TACHOMETER
IGNITION
19 o-
BRAKE
lO-
CHECK ANTI-LOCK
6 o-
SHIFT
5 o-
n
MALFUNCTION INDICATOR
2 o-
S E R V I C E REMINDER
INDICATOR
4 o
[
IGNITION
3 o-
L.H. TURN
21- 18 o -
R.H. TURN
7 o-
HIGH BEAM
17 o -
SEAT BELT
16 o -
EXPORT
MASTER LIGHTING ONLY
8 o-
ILLUMINATION 4 BULBS
21 o -
EXPORT
HAZARD ONLY
15 o -
10 o -
GROUND
20 o -
11 o -
J938W-5 ELECTRICAL SCHEMATIC OF CLUSTER YJ 42

J
T0<Z1>3
ILLUMINATION LAMP
GROUND S P L I C E f- -Zl 18BK- E2 200R
( S E E SH 32) ( S E E SH 3 1 )
ENGINE O I L P R E S S U R E
NATURAL SENDING U N I T
IGNITION FEED- G60 1 8 G Y / Y L
G5 1 8 D B / W T ( S E E SH 2 3 )
( S E E S H 10)
o o
3 •
o n ENGINE COOLANT
3 • T E M P E R A T U R E SENDING UNIT
O Q
4WD INDICATOR LAMP• Ml G20 1 8 V T / Y L
Gl 18DG/GY
Ml an ( S E E SH 2 3 )
( S E E SH 8) O Q
13
IGNITION FEED
F U E L GAUGE- G5 1 8 D B / W T
TANK L E V E L ( S E E SH 10)
SENDING U N I T
G4 20DB
( S E E SH 5 5 )
TO<£>
ILLUMINATION LAMP -Zl 18BK-
> GROUND S P L I C E
E2 200R
( S E E SH 3 2 )
( S E E SH 3 1 )
YJ 43 GAUGE PACKAGE CONNECTOR J938W-5

E L E C T R I C A L SCHEMATIC
J938W-5 OF GAUGE PACKAGE YJ 44
SPLICE
( S E E SH 3 2 )
IN-LINE
CONNECTOR REAR 5 AMP F U S E
OF RADIO
YJ 45 RADIO SYSTEM J938W-5

F U S E #7
(20 AMP)
TO IGNITION
•F30 16R0 A3! 14BK/WT SWITCH
( S E E SH 10)
-X54 20VT
R I G H T FRONT I/P
SPEAKER
LEFT FRONT I/P

SPEAKER
RIGHT
HALO S P E A K E R
f \ +
—X52
r-X58
20DB/WT
20DB/0R
V
>»
00
.—T
J
35
C]2-
f +
X51 20BR/YL
X57 20BR/LB
V —T
LEFT
HALO SPEAKER
(RIGHT S I D E
OF S P E A K E R
ENCLOSURE)
-X56 20DB/RD
WITHOUT REAR HALO SPEAKERS
J938W-5 RADIO SYSTEM YJ 46

TO
IGNITION s A O O
SWITCH ^2 MBK/OR
( S E E SH 10)
HEATER/OFF
SWITCH
TO
A/C BLOWER
SWITCH
( S E E SH 4 8 , 5 0 )
YJ 47 HEATER SYSTEM J938W-5

koo MM/HD f TO I G N I T I O N SWITCH

A22 MBK/OR — J ( S E E SH 10)
FUSE #12
(25 AMP)
(ABOVE A/C
HOUSING)
BLACK
T0<G5
m 5} TO PASSENGER
SPLICE
( S E E SH 10)
COMPARTMENT
E IB A/C WIRING
ID' ( I F INSTALLED)
TO BACK-UP
LAMP S W I T C H
( S E E SH 7)
TO '— F30 16RD

• HEATER/OFF
SWITCH
TL
( S E E SH 4 7 )
zi T0<^30>
14BK
SPLICE
( S E E SH 2 4 ) 65 18DB/WT
TO<2>
SPLICE •
C91
( S E E SH 3 2 )
18LB
C21 18DB/YL
C21
18DB TO ENGINE
YL COMPARTMENT
A/C(IF INSTALLED)
V - C91 18LB
43* CD CD
(T3CD
cad C20
18BR
RD
BLACK
( L E F T OF
27 34 28
A/C A/C A/C
REQUEST COMPRESSOR SELECT
POWERTRAIN CONTROL MODULE (PCM) CLUTCH
(UNDER BULKHEAD CONNECTOR RELAY CONNECTOR
IN ENGINE COMPARTMENT) ( S E E SH 63)
J938W-5 PROVISIONS FOR A I R C O N D I T I O N I N G S . 5 L YJ 48

T0<G5
I 65 18DB/WT—£
SPLICE
( S E E S H 10)
TO B A C K - U P
LAMP S W I T C H
( S E E SH 7 )
G5
18DB
ENG-1 h
WT
G5 18DB/WT
A/C R E L A Y
(LOCATED I N
POWER D I S T R I B U T I O N
CENTER C3
( S E E SH 68) 18D8
BK
T0<Z^y¥1
SPLICE C20 18BR/RD
( S E E SH 8)
•Zl 16BK
2
HENG-lh
•C3 18DB/BK - 4>-

-C20 18BR/RD
HENG-lh
A/C LOW
PRESSURE C20
SWITCH 18BR
( R I G H T FRONT C13 RD
CORNER OF ENGINE 18DB
COMPARTMENT ABOVE OR
RECEIVER DRIER
HENG-1
-C21 18DB/YL 4>- C21 18DB/YL
1
C91 18LB
HENG-2h HENG-2
ENG-2h
AIR
CONDITIONING C91
COMPRESSOR C13 C20
18LB
(FRONT OF 18DB 18BR
ENGINE) OR RD
34 28 27
A/C A/C A/C
P0H A N R0L REQUEST
K, £ rS?!!I COMPRESSOR S E L E C T
MODULE I PCM J CI UTCH CONNECTOR
(UNDER BULKHEAD CONNECTOR RELAY ( S E E SH 64)
I N ENGINE COMPARTMENT)
YJ 43 AIR CONDITIONING SYSTEM-4.OL J938W-5

4 WIRING DIAGRAMS 8W - 1 1 1
A22 l 4 B K / 0 R 5 TO I 6 N I T I O N
{ s E S SWITCH
( I N A/C
HOUSING)
A/C
BLOWER
SWITCH
C2I I8DB/YL-1
- C91 1 8 L B
( L E F T OF
TO CIGAR
LIGHTER
( S E E SH 24)
U938W-5 AIR CONDITIONING SYSTEM-4 . OL YJ 50

SW - 112 WIRING DIAGRAMS
TO BACK-UP s
LAMP S W I T C H t SOFT
( S E E SH 7) LI TOP
18VT TO ONLY
BLACK
SEAT B E L T
( L E F T OF 6 ) C7 (8) (9) i
SWITCH
STEERING SPLICE
seesh31 ( S E E SH 3 6 )
COLUMN)
SSSSfil ( )
T BLACK
(ABOVE PARKING
D BRAKE HANDLE)
SPLICE
( S E E SH 3 0 ) LI 18VT/BK L62
18BR
L7 18BK/YL RD
TO
TURN/HAZARD -L62 18BR/RD
SWITCH
ASSEMBLY -L63 18DG/RD
( S E E SH 3 4 )
TO H E A T E D
REAR WINDOW
( S E E SH 5 4 )
LEFT • 16WT/BK
BACK-UP
LAMP
LEFT
TAIL.STOP I
TURN SIGNAL
LAMP i
L I C E N S E LAMP GROUND C I R C U I T
P R O V I S I O N FOR
T R A I L E R TOW WIRING
(AT LAMP)
YJ 51 REAR LIGHTING J938W-5

L62
18BR
RD*
16WT/BK•
RIGHT
BACK-UP
LAMP
L7 18BK/YL
-L62 18BR/RD
LI 18VT/BK
RIGHT
T A I L . STOP I
TURN SIGNAL
LAMP
J938M-5 REAR LIGHTING YJ 52

TO < A 6 > S P L I C E
(SEE SH 30)
A6
12RD
BK
FUSE # 6 GRAY
( 2 5 AMP)
(ABOVE PARKING
BRAKE L E V E R )
F81
14BR
— F81 14BR —
C16 18LB/YL C16 18LB/YL
C15 18BK/WT
H E A T E D REAR
C15
WINDOW S W I T C H
18BK
(MOMENTARY
WT
CONTACT)
TO
(UNDER INSTRUMENT SPLICE

PANEL R I G H T OF ( S E E SH 32)
Zl 20BK
3€ZII> CIS 14BK/WT-
L I F T G A T E CYLINDER
SUPPORTS
B K - O Z K 3CZE Z l 14BK-
HEATED REAR WINDOW
YJ 53 HEATED REAR WINDOW SYSTEM ussew-s

TO <ly2\ SPLICE
(SEE SH 31)
TO < G ^ > S P L I C E J - 65 18DB/WT-
( S E E SH 10)
Zl
14BK
8
CIS 14BK/WT-
• • • • • • • • 16
ffi=L
-C15 18BK/WT
5 1
L / T " BLACK
65 18DB/WT- < ] f ^ [ > f - Z l 18BK (ABOVE
PARKING
BRAKE)
C16 18LB/YL- •F81 HBR
-FBI 14BR-
-C16 18LB/YL-
3 /
TO SEATBELT
HEATED SWITCH
REAR ( S E E SH 3 6 )
WINDOW
RELAY
(BEHIND
PARKING
BRAKE
PEDAL)
TO T A I L LAMP
-C15 18BK/UT- Zl 18BK Zl 14BK- ( S E E SH 5 1 )
GQffOG p 10
C15 14BK/WT• 100000 5
BLACK
. C 1 5 MBK/WT jfoQQQQ h
P
ROOF
HARNESS
msm
CONNECTOR
h
P (ABOVE L E F T
REAR T A I L LAMP)
10
TO REAR
Zl 14BK Zl 14BK- 4 W I P E R MOTOR
>
( S E E SH 37)
J938W-5 HEATED REAR WINDOW SYSTEM YJ 54

J
TO
TO < Z 1 > 7 | S P L I C E GAUGE PACKAGE
F U E L GAUGE
(SEE SH 11,17)
( S E E SH 43)
( L E F T S I D E OF
A141 16DG/BK •
TO F U E L
PUMP R E L A Y
( S E E SH 1 1 . 1 7 )
ENGINE
GROUND
(RIGHT
REAR DASH
PANEL
TO T R A N S M I S S I O N
WIRING
( S E E SH 7 )
F U E L TANK
SENDING U N I T
AND F U E L PUMP
( I N F U E L TANK)
YJ 55 FUEL TANK SYSTEM J938W-5

R I G H T REAR L E F T REAR
WHEEL SENSOR WHEEL SENSOR
(UNDER D R I V E R S SEAT)
ABS
ACCELERATOR
SENSOR
1 ^ 2
TWISTED PAIR
B4 18LG-
L
B 3 18LG/DB -
•B2 18YL
Bl 18YL/DB
TWISTED PAIR
II 13
ENG-1 ENG-1
12 - ENG-1 -
R I G H T FRONT L E F T FRONT
- ENG-1 -
WHEEL SENSOR WHEEL SENSOR
TWISTED
PAIR
68 83 Bl B22 B21 B23

B9 B4 B2
18WT 18RD 18LG 18YL 18VT 18YL 18PK
I SWT 18RD 18LG 18YL
DB DB DB PK VT BR
TWISTED
TWISTED
PAIR
PAIR
29 47 30 48 46 28 27 45 43 25 26
— + _ + +
(CENTER REAR OF I.P)
ABS CONTROL MODULE CONNECTOR ( S E E S H 59)
J938W-5 ANT I-LOCK BRAKE SYSTEM (TEVES) YJ 56

F10 30A
BATTERY FEED
BUS BAR
F9 40A
POWER DISTRIBUTION
CENTER - ( S E E SH 6 )
F15 18YL/DG •
ABS
POWER
RELAY
Z12 12BK/TN-
( I N POWER
DISTRIBUTION Z12 12BK/TN-
CENTER) BODY
( S E E SH 6 8 ) Zl 14BK- = " GROUND
( R I G H T REAR
j TO<Zl2i|SPLICE DASH P A N E L )
(SEE SH 8)
B15 14GY/YL-
ABS MOTOR
BRAKE PUMP R E L A Y
PEDAL T R A V E L
SENSOR
IN POWER
DISTRIBUTION
CENTER)
(ON S E E SH 6 8 )
BRAKE
BOOSTER)
2 Q
DATA L I N K
B25 12TN-
CONNECTOR
6
B258 B210
( L E F T REAR
ENGINE
TO<M^yn SPLICE
COMPARTMENT) SEE SH 8
P} \
18GY 18RD
LB BK B20
D12 B l 16
18PK
uj
u180R 18GY TWISTED
s. 1 ^ & ^ PAIR
i" T T
16 41 34 23 42 15 49 31
(CENTER REAR OF I.P)

ABS CONTROL MODULE CONNECTOR ( S E E SH 59)
YJ 57 ANTI-LOCK BRAKE SYSTEM (TEVES) J938w-s

TO IGNITION SWITCH
( S E E SH 10)
HYDRAULIC
ACTUATION
UNIT
VALVE BODY
( I N ENGINE COMPARTMENT
L E F T FENDER SHIELD)
TO STOP LAMP
SWITCH
( S E E SH 3 4 )
L50
18WT
TN
( R I G H T REAR
DASH P A N E L )
BODY GROUND
L50
18WT
TN
Zl
14BK
Zl
14BK
52 3 33 53 54 38 20 2 21 36 32 1 19
(CENTER REAR OF L P )
ABS CONTROL MODULE CONNECTOR ( S E E SH 59)
J938W-5 ANTI-LOCK BRAKE SYSTEM (TEVES) YJ 58

8 W - 120 WIRING DIAGRAMS
J
CAV IGNITION SYSTEM C I R C U I T S

1 Zl 14BK GROUND
2 B 2 4 3 16DG/BK L E F T FRONT DECAY VALVE
3 815 14GY/YL POWER R E F E R E N C E
—
4
—
5
— —
6
— —
7
— —
8
— —
9
—
• • 10
11
12
—
—
—
—
—
20_
13
14
—
—
—
38 15 Bl16 18GY PUMP CONTROL
§§ 16 B258 18GY/LB PEDAL T R A V E L SENSOR
17 —
§§
§§
18
19
—
Zl 14BK
—
GROUND
20 B245 16WT/LG L E F T FRONT I S O L A T E VALVE
S3 21 B 2 4 8 16DG/WT R I G H T FRONT DECAY VALVE
S3 22 — —
§§ 23 Dl1 18WT/VT DATA LINK - CCD BUS (+)
24 — —
oe 25 B21 18YL/VT G S W I T C H - 1 (ACCEL SENSOR)
26 B23 18PK/BR S W I T C H T E S T SIGNAL
eg
27 Bl 18YL/DB R I G H T REAR SENSOR H
S3 28 L E F T , R E A R SENSOR (—)
S3 B3 18LG/DB
29 86 18WT/DB R I G H T FRONT SENSOR (-)
§§ 30 B8 18RD/DB L E F T FRONT SENSOR (—)
31 B16 18BR MOTOR SENSOR (—)
§§ 32 BRAKE SIGNAL
L50 18WT/TN
37
33 B15 14GY/YL S Y S T E M POWER
34 B20 18PK POWER CONTROL R E L A Y
35
36
—
B254 16DG/0R
—
REAR DECAY VALVE
VIEWED FROM —
T E R M I N A L END
37
38 B249 16WT/YL
—
RIGHT FRONT ISOLATE VALVE
39 — —
40
41
—
B210 18RD/BK
—
PEDAL T R A V E L SENSOR GROUND
42 D12 180R DATA L I N K - CCD B U S (—)
43 B22 1 8 V T / P K G S W I T C H - 2 (ACCEL SENSOR)
44 — —
45 B2 18YL R I G H T REAR SENSOR ( + )
46 B4 18LG L E F T REAR SENSOR ( + )
47 B7 18WT R I G H T FRONT SENSOR ( + )
48 B9 18RD L E F T FRONT SENSOR ( + )
49 B17 18LG/BR MOTOR SENSOR ( + )
50
— —
51
52
—
G19 20LG/0R
—
WARNING L I G H T (YELLOW)
53 F15 18YL/0G I G N I T I O N 12V
54 B251 16WT/BK REAR I S O L A T E VALUE
—
55
—
YJ 59 ABS CONTROL MODULE CONNECTOR J938W-5

INSTRUMENT PANEL
HIRING
D E F G H J K L M N P
STRG
COLUMN
0 E F G H J K L M N P
CAV T U R N SIGNAL SWITCH CIRCUITS SHEET
P L50 18WT/TN STOP LAMPS 34

N L62 18BR/RD RIGHT TURN-REAR 34
M L63 18DG/RD LEFT TURN-REAR 34
L L6 18RD/WT TURN SIGNAL FLASHER 34
K L19 18PK HAZARD FLASHER 34
J L60 18TN RIGHT TURN-FRONT/INDICATOR 34

J L60 18TN RIGHT TURN-FRONT/INDICATOR 34
H L61 18LG LEFT TURN-FRONT/INDICATOR 34
H L61 18LG LEFT TURN-FRONT/INDICATOR 34
G X3 18BK/RD HORN S W I T C H 33
F G26 18LB I G N I T I O N KEY WARNING S W I T C H 36
E G16 18BK/LB I G N I T I O N KEY WARNING S W I T C H 36
0 E2 200R TRANSMISSION RANGE ILLUMINATION 32
J938H-5 S T E E R I N G COLUMN CONNECTOR YJ 60

FUSE
AMPS COLOR DESCRIPTIONS SHEET
NUMBER
1 20 YELLOW REAR WIPERS 2,10,37
2
3 15 LT BLUE STOP LAMPS & B U Z Z E R 1.30,34,36
4 15 LT BLUE T U R N S I G N A L LAMPS 2,10,34
5 10 RED A.S.D. 1 F U E L PUMP R E L A Y S 2.10,13.19
6 25 NATURAL HEATED REAR WINDOW 1.30.53
7 20 YELLOW CIGAR L I G H T E R & ACC 2.10,24.46
8 20 YELLOW RUNNING LIGHTS 1.29
9 15 LT BLUE BUZZER,GAUGES & WARNING 2.10.36
LIGHTS I R E L A Y S 8 BACKUP LAMPS
10 5 TAN PANEL ILLUM. LAMPS 1.31
11 5.3 C/B GOLD FRONT WIPERS & WASHERS 2.10.38.39
12 25 NATURAL HEATER 8 A/C 2,10.47,48.50
YJ 61 FUSE PANEL J938W-5

TURN SIGNAL L6 18RD/WT

FLASHER
( S E E SH 34) L5 18BK
G50 18WT/YL
A2I 14DB
F33 18PK/RD
HAZARD
SIGNAL L19 18PK
FLASHER L9 18BK/WT
( S E E SH 3 4 )
AG 12RD/BK
A22 14BK/0R
A22 14BK/0R
V23 16BR/PK
F32 18PK/DB
A6 1 8 R D / B K
F32 18PK/DB
L5 18BK
F81 14BR
AS 12RD/BK
G5 18DB/WT
A31 14BK/WT
G5 18DB/WT
A21 14DB
CI 14DG
A21 14DB
F30 I6RD •CI 14DG

A22 14BK/0R
A22 14BK/0R
A31 14BK/WT-
o •V6
•V6
18DB
18DB
El 20TN-
G5 18DB/WT
E2 200R •
G26 18LB SEATBELT/
A31 14BK/WT•
G13 20DB/RD IGNITION
KEY WARNING
F32 18PK/DB
BUZZER
Zl 20BK ( S E E SH 3 6 )
G10 18LG/RD
J938W-5 FUSE PANEL YJ 62

J
CAV ECM S Y S T E M C I R C U I T S
1 Kl 20DG/RD MAP SENSOR ( + )
2 K2 18TN/BK ENGINE COOLANT T E M P . S E N S O R
3 A14 16RD/WT BATTERY
4 K4 18BK/LB SENSOR GROUND
5 Zll 16BK/WT GROUND SENSOR FOR F U E L
6 K6 20VT/WT SENSOR R E T U R N
7 K7 180R V E H I C L E S P E E D SENSOR-MAG(+)
8
9
—
G5 1 8 D B / W T I G N I T I O N I - S T A R T AND RUN
10 KIO 1 8 D B / 0 R POWER S T E E R I N G SENSOR F E E D
11 Z l 16BK GROUND
12 Z l 16BK GROUND
13 K14 1 8 L B / B R I N J E C T O R NO.4
14 K13 1 8 Y L / W T INJECTOR NO.3
15 K12 18TN INJECTOR NO.2
16 Kll 18WT/DB I N J E C T O R NO.1
17
—
—
—
18
19 K19 18GY
—
IGNITION
20 K20 18DG GENERATOR F I E L D
21 K21 18BK/RD I N T A K E A I R T E M P E R A T U R E SENSOR
22 K22 180R/DB THROTTLE POSITION (SENSOR)
23
24
—
K24 18GY/BK
—
V E H I C L E S P E E D SENSOR MAG(—)
25 D21 20PK DATA L I N K ( D A T A - 2 )
26 —
27 C91 18LB A/C R E Q U E S T
28 C20 18BR A/C S E L E C T
29 V40 18WT/PK TCC F E E D ( B R A K E )
|10|3|S|7|5|5H|3|2|I
30 T41 18BR/YL P A R K / N E U T R A L P O S I T I ON(SWITCH)
i i r
31
32
— 20BK/PK
63
—
MALFUNCTION INDICATOR LAMP
II I I I I i I I [
=•=
I 33
34
— 18DB/0R
C13
—
A/C COMPRESSOR CLUTCH R E L A Y
35 — —
—
VIEWED FROM W I R E
36
— —
END OF CONNECTOR
37
—
—
38
39 K39 18GY/RD
—
I D L E A I R CONTROL S T E P P E R
40 K40 18BR/WT I D L E A I R CONTROL S T E P P E R
41 K41 18BK/DG H E A T E D OXYGEN SENSOR
42
43
—
G21 20GY/LB
—
B U F F E R E D TACH SIGNAL
44 K44 18TN/YL CAMSHAFT P O S I T I O N SENSOR SIGNAL
45 020 20LG DATA L I N K ( D A T A - 1 )
—
46
47
— 20WT/0R
67 VEHICLE SPEED SIGNAL
48
— —
49
— —
50
51
—
K51 1 8 D B / Y L
—
F U E L PUMP R E L A Y COIL
52
——
—
53
54 K54 200R/BK
—
U P S H I F T LAMP
—
55
56
—
G24 20GY/PK S E R V I C E REMINDER INDICATOR LAMP
57 A142 18VT/BK ASD B A T T E R Y S E N S E
—
58
59 K59 18VT/BK
—
IDLE AIR CONTROL STEPPER
60 K60 18YL/BK IDLE AIR CONTROL STEPPER
POWERTRAIN CONTROL MODULE CONNECTOR

YJ 63 (2.5L ENGINE) J938H-5
CAV ECM S Y S T E M C I R C U I T S
1 K l 20DG/RD MAP SENSOR ( + )
2 K2 1 8 T N / B K E N 6 I N E COOLANT T E M P . S E N S O R
3 A14 1 6 R D / W T BATTERY
4 K4 1 8 B K / L B SENSOR GROUND
5 Z l l 16BK/WT GROUND SENSOR FOR F U E L
6 K6 2 0 V T / W T SENSOR R E T U R N
7 K7 1 8 0 R V E H I C L E S P E E D SENSOR-MAG(+)
8
9
— 18DB/WT
G5
—
IGNITION I-START AND RUN
10
11
—
Z l 16BK
—
GROUND
12 Z l 16BK GROUND
13 K14 1 8 L B / B R INJECTOR NO.4
14 K l 3 18YL/WT INJECTOR NO.3
15 K12 1 8 T N INJECTOR NO.2
16 Kll 18WT/DB INJECTOR NO.1
17
— —
18
19
—
K 1 9 18GY
—
IGNITION
20 K20 18DG GENERATOR F I E L D
21 K21 1 8 B K / R D I N T A K E A I R T E M P E R A T U R E SENSOR
22 K22 1 8 0 R / D B THROTTLE POSITION (SENSOR)
23
24
—
K24 18GY/BK V E H I C L E S P E E D SENSOR MAG(—)
25 D21 20BK DATA L I N K ( D A T A - 2 )
26 — ....
27 C91 1 8 L B A/C R E Q U E S T
28 C20 18BR A/C S E L E C T
29 V40 1 8 W T / P K TCC F E E D ( B R A K E )
IIO S "f 7 1,11, 4 3 2 i
30 T41 18BR/YL P A R K / N E U T R A L P O S I T I ON(SWITCH}
• ztz • l • • I
rr @ L J I I I I—L_J—I—I—I,
31
32
33
34
—-
G3
—
C13
20BK/PK
18DB/0R
—
MALFUNCTION INDICATOR
—
A/C COMPRESSOR
LAMP
CLUTCH R E L A Y
—
35
—
VIEWED FROM W I R E
36
— —
END OF CONNECTOR
37
38
—
K15 18PK/BK I N J E C T O R NO.5
39 K39 18GY/RD I D L E A I R CONTROL S T E P P E R
40 K40 18BR/WT I D L E A I R CONTROL S T E P P E R
41 K41 18BK/DG H E A T E D 0XY6EN SENSOR
42
43
—
621 20GY/LB
—
B U F F E R E D TACH SIGNAL
44 K44 18TN/YL CAMSHAFT P O S I T I O N SENSOR SIGNAL
45 D20 20LG DATA L I N K (DATA l )
46
47
—
G7 20WT/OR
—
VEHICLE S P E E D SIGNAL
48 — —
49
— —
50
51
—
K51 18DB/YL
—
F U E L PUMP R E L A Y COIL
52
— —
53
54
—
K54 200R/BK
—
U P S H I F T LAMP
55
— —
56 624 20GY/PK S E R V I C E R E M I N D E R INDICATOR LAMP
57 A142 18DG/0R ASD B A T T E R Y S E N S E
58 K16 18LG/BK I N J E C T O R NO.6
59 K59 1 8 V T / B K I D L E A I R CONTROL S T E P P E R
60 K60 1 8 Y L / B K I D L E A I R CONTROL S T E P P E R
POWERTRAIN CONTROL MODULE CONNECTOR

J938W-5 ( 4 . 0 L ENGINE) YJ 64
CAV ENGINE COMPARTMENT CIRCUITS SHEET
Al L7 18BK/YL PARKING LAMPS 26,28,30

A2 V20 18BR/WT REAR WASHER PUMP 37
A3 L60 18TN RIGHT T U R N SIGNAL LAMPS 25.27,34
A4 619 20LG/BR ABS WARNING L I G H T 58
A5 A22 18BK/0R IGNITION FEED (RUN ONLY) 58
A6 L50 18WT/TN STOP LAMP 58
A7 G9 20GY/BK BRAKE WARNING S W I T C H 9
Bl L20 16LG/WT DAYTIME RUNNING LAMPS 28,29
B2 G5 18DB/WT DAYTIME RUNNING LAMPS 28
B3
— —
B4 67 18WT/0R VEHICLE SPEED SIGNAL 12,18
B5 Zl 14BK GROUND 8,31
B6 611 20WT/BK BRAKE B U L B CHECK 9
CI 67 18WT/0R VEHICLE S P E E D SENSOR 12,18,28
C2 LG1 18LG LEFT T U R N SIGNAL LAMPS 25,27,34
C3
— — —
624 206Y/PK S E R V I C E REMINDER INDICATOR 16,22
C4
GROUND
C5 63 20BK/PK MALFUNCTION INDICATOR LAMP GROUND 16,2?
C6 65 18DB/WT BACKUP LAMP S W I T C H 1 7,48,49
A/C R E L A Y
•••••••• Dl L39 16LB FOG LAMP FEED 26,28,30

D2 — — —
D4 L9 18BK/WT HAZARD FLASHER FEED 4,6
• I /^NlDD^ 10,13,19
D5 650 18WT/YL IGNITION I-START AND RUN
El L3 16RD/0R HIGH BEAM HEADLAMPS 25.27,29
El 634 18RD/GY HIGH BEAM I N D I C L P W/0 DRL 25
( • U n U U n •u n
E2 G34 18RD/GY HIGH BEAM I N D I C L P W/0 DRL 26
E2 28
••••••• E4
G34
A3
18RD/GY
12RD/0R
HIGH BEAM
HEADLAMP
INDIC L P WITH DRL
SWITCH FEED 4,6,29
E5
— — —
H G F E D C B A Fl — — —
F2 — — —
F3 V10 18BR WINDSHIELD WASHER PUMP FEED 38,39
ENGINE COMPARTMENT
F4
— —
F5 — — —
F6 K54 200R/BK UPSHIFT SWITCH 13.19
61
— — —
62 — — —
63 X2 18DG/RD HORN 33
G4 A6 12RD/BK FUSEBLOCK FEED 4.6,30
65 A41 18YL STARTER RELAY-CRANK 7
G6 X2 18D6/RD HORN R E L A Y 33
HI L4 16VT/WT LOW BEAM HEADLAMPS 25,27,29
H2 — — —
H3 — — —
H4 Ml 18PK I.O.D. BATTERY FEED 8,35
H5 V40 18WT/PK S T O P LAMP SWITCH 16.22.34
H6 621 206Y/LB TACHOMETER SIGNAL 16.22
YJ 65 BULKHEAD CONNECTOR J938H-5

CAV I N S T R U M E N T PANEL CIRCUITS
Al L7 18BK/YL PARKING LAMPS F E E D

A2 V20 18BR/WT REAR WASHER PUMP (HARD TOP)
A3 L60 18TN RI6HT TURN S I 6 N A L LAMPS
A4 619 20LG/OR ABS WARNIN6 L I 6 H T
A5 A22 14BK/0R I6NITI0N FEED (RUN ONLY)
A6 L50 18WT/TN STOP LAMP FEED
A7 G9 20GY/BK BRAKE WARNING INDICATOR LAMP
Bl L20 16LG/WT HEADLAMP DIMMER SWITCH
B2 G5 180B/WT SPLICE (FUSE BLOCK)
B3
— —
B4 G7 20WT/0R VEHICLE S P E E D SENSOR SIGNAL
B5 Zl 14BK GROUND
B6 611 20WT/BK BRAKE WARNING S W I T C H
CI 67 20WT/OR V E H I C L E S P E E D SENSOR SIGNAL
C2 L61 18LG LEFT T U R N SIGNAL LAMPS
C3 — —
C4 G24 206Y/PK S E R V I C E REMINDER INDICATOR
GROUND
C5 G3 20BK/PK MALFUNCTION INDICATOR LAMP GROUND
C6 65 180B/WT B A C K - U P LAMP S W I T C H I
A/C R E L A Y
01 L39 16LB FOG LAMPS
D2
— —
04 L9 18BK/WT HAZARD FLASHER FEED
05 G50 18WT/YL IGNITION I-START AND RUN
El L3 16RD/0R DIMMER SWITCH-HIGH BEAM
E2 G34 18RD/6Y H I 6 H BEAM INDICATOR LAMP
E4 A3 12RD/0R HEADLAMP SWITCH

E5 — —
Fl — —
I N S T R U M E N T PANEL
F2 — —
F3 V10 18BR W I N D S H I E L D WASHER PUMP FEED
F4
—
—
—
F5 —
F6 K54 200R/BK UPSHIFT INDICATOR
61 —
—
GZ
— —
G3 X2 18DG/RD HORN
G4 A6 12RD/BK FUSEBLOCK FEED
G5 A41 18YL IGNITION SWITCH-START
66 X2 18DG/RD HORN R E L A Y
HI L4 16VT/WT DIMMER SWITCH-LOW BEAM
—
H2 —
H3
— —
H4 Ml 18PK I.O.D. BATTERY FEED
H5 V40 18WT/PK S T O P LAMP SWITCH
(2) INDICATES-2 W I R E S IN CAVITY
H6 621 206Y/LB TACHOMETER SIGNAL
J938W-5 BULKHEAD CONNECTOR YJ 66

RELAY DESCRIPTION
A HORN RELAY
B F U E L PUMP R E L A Y
C ABS PUMP R E L A Y
D A/C COMPRESSOR CLUTCH R E L A Y
E AUTOMATIC S H U T DOWN R E L A Y
F ENGINE S T A R T E R R E L A Y
G ABS POWER R E L A Y
-SPARE FUSE HOLDER FOR I . O . D . F U S E DURING S H I P M E N T
FUSE AMPS COLOR DESCRIPTION TYPE

Fl 30A GREEN FUEL PUMP & AUTOMATIC S H U T DOWN
F2 50A RED CHARGING C I C U I T
F3 50A RED B A T T E R Y ACC F E E D
F4 40A AMBER I G N I T I O N & ENGINE S T A R T E R FEED
F5 20A YELLOW HAZARD F L A S H E R F E E D MAXI
F6 50A RED CHARGING C I R C U I T FUSE
F7 30A GREEN HEADLAMP F E E D
F8 20A YELLOW I . O . D . E HORN F E E D
F9 40A AMBER ABS PUMP R E L A Y
FIO 30A GREEN ABS POWER R E L A Y
Fll
F12
F13 2A GRAY ABS CONTROL MODULE MINI
F14 FUSE
F15 lOA RED HORN / HORN R E L A Y
Fl6 10A RED I O.D. CIRCUITS
POWER DISTRIBUTION CENTER

YJ 67 IDENTIFICATION COVER J938W-5
x
47 46 45 44 43 4 2 ^ 1
1 1
12 13
10
34 29 24 19 M 41 40 39 38 37 3 6
35 31 30 26 25 21 20
62Dcranei ioS^b.
h c3S|caca^coK]^K]C3^[a.fl^DuK]^raGa^ca
1 , 4
i6 5 —
u 59D dm
Da Co ca ca gj ca ca 22
E
VIEWED FROM T E R M I N A L S I D E
(LOCATED ON R I G H T S I D E OF ENGINE COMPARTMENT)
A
CAV
HORN R E L A Y
CIRCUIT
B
CAV
FUEL PUMP R E L A Y
CIRCUIT
c
CAV
ABS PUMP R E L A Y
CIRCUIT
1 X3 18BK/RD 6 G50 18WT/YL 11 B15 18GY/YL
2 F31 18VT A14 16RD/WT 12 AlO 12RD/BR
7
4 X2 18DG/RD A14 16RD/WT 14 B25 12TN
F31 18VT 9 A141 16DG/BK 15 B l 16 18GY
5
F31 18VT K51 18DB/YL 60 Z12 18BK/TN
10
( S E E SH 33) K51 18DB/YL ( S E E SH 5 7 )
(SEE SH 1 1 , 1 7 )
A/C COMPRESSOR
D
CLUTCH R E L A Y E AUTOMATIC S H U T DOWN F ENGINE S T A R T E R RELAY
CAV CIRCUIT CAV CIRCUIT CAV CIRCUIT
16 C13 18DB/0R 21 G50 18WT/YL 26 A41 18YL
17 C3 16DB/BK A14 16RD/WT 27 Al 12RD
22
18 Zl 16BK A14 16RD/WT 29 T40 14BR
C20 18BR/RD A142 16DG/0R T41 18BR/YL
19 24 30
C20 18BR/RD A142 16DG/0R T41 18BR/YL
65 18DB/WT 25 K51 18DB/YL (SEE SH 7 )
20
65 18DB/WT (SEE SH 1 1 , 1 7 )
( S E E SH 49)
6 ABS POWER R E L A Y
CAV CIRCUIT
31 F15 18YL/DG
B15 14GY/YL
32
B15 18GY/YL
33 Z12 18BK/TN
34 A20 14RD/DB
35 B20 18PK
(SEE SH 5 7 )
J938W-5 POWER DISTRIBUTION CENTER RELAYS YJ 68

J
J'L—d"L
V
y
II II
II II II
/II I In
u — ^
ENGINE WIRING HEADLAMP & DASH WIRING
4.0L ENGINE 2 5 L ENGINE 4.0L ENGINE 2 5 L ENGINE

CAV CIRCUIT INFO CIRCUIT INFO CAV CIRCUIT INFO CIRCUIT INFO
1 C20 18BR/RD C20 18BR/RD 1 T 4 0 14BR T40 14BR
2 C91 1 8 L B C91 1 8 L B 2 C3 1 8 D B / B K
3 A14 16RD/WT A14 16RD/WT 3 A141 16DG/BK A141 16DG/BK
4 C13 18DB/0R C13 18DB/0R 4 G4 18DB 64 18DB
5 63 20BK/PK G3 20BK/PK 5 A142 18DG/0R A142 18DG/0R
6 650 18WT/YL G50 18WT/YL 6 C21 18DB/YL 67 18WT/0R
7 620 18VT/YL G20 18VT/YL 7 C20 18BR/RD
8 T41 18BR/YL A142 18DG/0R 8 L I 18VT L I 1BVT
9 V40 18WT/PK V40 18WT/PK 9 G5 18DB/WT 65 18DB/WT
10 K51 18DB/YL K51 18DB/YL 10 T41 18BR/YL K4 1SBK/LB
11 K54 20QR/BK K54 200R/BK 11 B4 18LG K7 1 8 0 R
12 G21 20GY/LB G21 20GY/LB 12 B3 18LG/DB
13 624 20GY/PK G24 20GY/PK 13 Bl 18YL/DB
14 67 18WT/0R G7 18WT/0R 14 B2 1 8 Y L
15 K4 18BK/LB K4 18BK/LB 15 G60 18GY/YL 660 186Y/YL
16 K7 180R 16
ENG-2 ENG-1 -
CONNECTOR LOCATED L E F T CONNECTOR LOCATED R I G H T

S I D E - NEAR BULKHEAD S I D E - NEAR A L T E R N A T O R
YJ 69 ENGINE WIRING CONNECTOR (16 WAY) J938W-5

WIRING DIAGRAMS 8W - 1 3 1
WIRING DIAGRAMS XJ
INDEX
A/C Compressor Clutch Relay . .3, 65 Seat Belt Switch 70
A/C Compressor Clutch 65 Cigar Lighter 35
A/C Heater Blower Motor 66 Cigar Lighter Lamp .46
A/C Low Pressure Switch 65 Circuit Breakers
A/C Mode Select Switch . .66 In Line Circuit Breaker 2, 74
A/C Thermostat 65 Trailer Tow In-Line Circuit Breaker 91
ABS Diode .31 Windshield Wiper Circuit Breaker .59, 60
ABS Green Indicator Lamp .53 Connectors
ABS Hydraulic Actuation Unit 31 Data Link Connector 16, 18, 25, 30
ABS # 1 Relay 3, 29 Instrument Cluster Connector 16 Way 5 1 , 102
ABS # 2 Relay 3, 29 Main Body Connectors .106
ABS Pump Motor 28 Steering Column Connector 11 Way . .100
ABS Red Indicator Lamp . .53 Telltale Connector . . .52, 101
Antenna .67 Crankshaft Position Sensor 1 1 , 20
Antenna Mast 67 Cooling Fan Relay 3, 23
Anti-Lock Braking System 27, 28, 29, 30, 31 Data Link Connector 16, 18, 25, 30
ABS Diode 31 Daytime Running Lamp Module (DRL) 36
ABS Relays . .29 Daytime Running Lamp System 36
Anti-Lock Pump Motor .28 Diode, ABS 31
Anti-Lock Brake System Module . .27, 28, 29, 30, 31 Distributor Ignition Coil .16, 18
Data Link Connector .30 Dome Lamp 49
G Sensor 28 Dome and Courtesy Lamps . .47, 48, 49
Hydraulic Actuation Unit . 31 Cargo Lamp 48
Left Front Wheel Sensor .27 Dome/Reading Lamp 49
Left Rear Wheel Sensor .27 Dome Lamp 49
Anti-Lock Brake Control Module Connector 103 Glove Box Lamp 47
Pedal Travel Sensor 28 Dome/Reading Lamp 49
Right Front Wheel Sensor 27 Left Courtesy Lamp 47
Right Rear Wheel Sensor .27 Reading Lamp 49
Anti-Lock Brake System Module . . . . . . . .27, 28, 29, 30, 31 Right Courtesy Lamp 47
Anti-Lock Pump Motor .28 Vanity Lamps 49
Anti-Lock Relay 29 Dome Reading Lamp 49
Ashtray Lamp .46 Door Jamb Switch System 7 1 , 72
Automatic Shut Down Relay .3, 12, 17 Left Front Door Jamb Switch . . .71
Back-Up Lamp Switch 25 Left Rear Door Jamb Switch 71
Ballast Resistor .85 Liftgate Switch 72
Ballast Resistor By-Pass Relay .85 Right Front Door Jamb Switch 72
Battery 1 , 7, 8 Right Rear Door Jamb Switch . .72
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .64, 66 Engine Block Coolant Heater/Cigar Lighter 35
Blower Resistors . . . . . . . . . . . . . . . . . . . . . . . . . .64, 66 Cigar Lighter . . . .35
Blower Switch . .64, 66 Engine Block Coolant Heater . . .35
Body Ground 42 Wall Plug 35
Brake Warning Switch 63 Engine Block Heater 35
Bulkhead Disconnect 95, 96, 97, 98 4 WD Indicator Lamp 26, 53, 54
Camshaft Position Sensor 1 1 , 20 Engine Coolant Temperature Sending Unit .24
Cargo Lamp .48 Engine Coolant Temperature Sensor .14, 19
Charging System 2.5L . .5 Engine Coolant Temperature Switch 24
Generator 5 Engine Oil Pressure and Temperature System 24
Charging System 4.0L .6 Engine Coolant Temperature Switch . 24
Generator 6 Engine Oil Pressure Switch 24
Chime Module 70 Engine Starter Motor . . .7, 8
Ignition Key Warning Switch 70 Engine Starter Relay .3, 7, 8

J
Engine Starter System (2.5L) .7 Engine Coolant Temperature Sensor . 19
Battery • 7 Fuel Pump Relay 17
Engine Starter Motor 7 Heated Oxygen Sensor 21
Engine Starter Relay . 7 Idle Air Control Motor .22
Engine Starter System (4.0L) 8 Intake Air Temperature Sensor . 19
Battery . .8 Injectors .22
Engine Starter Motor .8 MAP Sensor 19
Engine Starter Relay .8 Powertrain Control Module .17, 18, 19, 20, 2 1 , 22
Fan Control Relay • 23 Throttle Position (Sensor) 19
Fog Lamp Illumination 40, 45 Vehicle speed Sensor 20
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Fuel Injector(s) . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 22
Fog Lamp Switch .40 Fuel Pump Relay .3, 12, 17
Front Axle Switch . 26 Fuel Tank Level Gauge Sending Unit 86
Front Door Lock and Window Switch Functions 83 Fuel Tank Systems • -85, 86
Front End Lighting 37, 38 Ballast Resistor By-Pass Relay 85
Fog Lamp Relay 37 Ballast Resistor . . . .85
Left Fog Lamp 37 Fuel Tank Level Gauge Sending Unit 86
Left Headlamp 37 Fuse Application Chart 1,2
Left Park/Turn Signal Lamp 37 Fuses Panel .93, 94
Left Side Marker Lamp 37 Fuses
Right Fog Lamp .38 F1 .-.3,4
Right Headlamp 38 F2 .3, 4, 12, 17
Right Park/Turn Signal Lamp 38 F3 ........3,4
Right Side Marker Lamp 38 F4 3, 4
Front Washer Pump • .59, 60 F5 3,4
Front Wiper Motor . .59, 60 F6 3, 4
Front Wipers/Washer (Intermittent) 60 F7 -3,4
Front Washer Pump .60 F8 3,4
Front Wiper Motor 60 F9 .....3,4
Wiper/Washer Switch . .60 F10 3, 4
Intermittent Wiper Module 60 F11 ................3,4
Front Wipers/Washer (Standard) 59 F12 .3, 4
Front Washer Pump . .59 F13 . .3, 4
Front Wiper Motor 59 F14 3, 4
Wiper/Washer Switch 59 F15 ....3,4
Fuel Injection Ignition System (2.5L) . . 1 1 , 12, 13, 14, 15, 16 F16 .3, 4
Automatic Shut Down Relay 12 Fuse # 1 2, 10, 61
Camshaft Position Sensor .11 Fuse # 2 2, 9, 35, 67
Crankshaft Position Sensor 11 Fuse # 4 • ..1,39
Data Link Connector 16 Fuse # 5 .2, 59, 60, 64, 66
Distributor Ignition Coil . .16 Fuse # 7 . . .2, 10, 30
Engine Coolant Temperature Sensor . 14 Fuse # 8 • 2, 43, 62
Fuel Pump Relay 12 Fuse # 9 1 , 4, 47
Heated Oxygen Sensor . .13 Fuse # 1 1 . . 1 , 4 1 , 79
Idle Air Control Motor 15 Fuse #13 •• 79
Injectors .15, 22 Fuse # 1 5 . . . . . . . . . . . . . . . . . . 1 , 39
Intake Air Temperature Sensor .14 Fuse # 1 7 2, 10, 5 1 , 70
MAP Sensor 14 Fuse #18 1 , 62
Power Steering Pressure Switch 15 Fuse # 1 9 1 , 39, 45
Powertrain Control Module 1 1 , 12, 13, 14, 15, 16 Gauges
Throttle Position (Sensor) .14 Engine Coolant Temperature Gauge 55, 56, 57
Vehicle speed Sensor 11 Engine Oil Pressure Gauge .55, 56, 57
Fuel Injection Ignition System (4.0L) . .17, 18, 19, 20, 2 1 , 22 Fuel Gauge -55, 56, 57
Automatic Shut Down Relay 17 Generator .5, 6
Camshaft Position Sensor 20 Hazard Flasher • • • .33, 44
Crankshaft Position Sensor 20 Headlamp Delay Module 41
Data Link Connector 18 Headlamp Dimmer Switch 39
Distributor Ignition Coil • .18 Headlamp Switch -39, 40
Fog Lamp Illumination . . . . . . . . . . . . . . . . . . . . . . .40 Instrument Panel Ground 58
Fog Lamp Switch .40 Instrument Panel Illumination 45, 46
Headlamp Dimmer Switch .39 Ashtray Lamp . .46
Headlamp Switch -39 Cigar Lighter Lamp 46
Headlamps 37, 38 Fog Lamp Illumination 45
Heat Mode Select Switch .64 Heater A/C Panel Lamp . 45
Heated Oxygen Sensor 13, 21 Heated Rear Window Switch Lamp 45
Heated Rear Window 62 Rear Wiper Wash Switch Lamp 45
Relay .62 Transfer Case Lamp 46
Grid •• . • • -62 Transmission Range Switch Lamp . . . . 46
Switch 62 Intake Air Temperature Sensor . .14, 19
Heater A/C Panel Lamp . . . . . . . . . . . . . . . . . . . . . . . .47 Intermittent Front Wipers/Washers 60
Heater and A/C System .65, 66 Intermittent Wiper Module 60
A/C Mode Selector Switch • .66 Keyless Entry Module 79
A/C Compressor Clutch 65 Lamps
A/C Compressor Clutch Relay .65 ABS Green Indicator Lamp 53
A/C Thermostat 65 ABS Red Indicator Lamp 53
A/C Low Pressure Switch 65 Ashtray Lamp 46
Blower Motor . .64 Cargo Lamp 48
Blower Resistor .66 Cigar Lighter Lamp 46
Blower Switch .66 Dome Lamp 49
Heat Mode Select Switch .64 Dome/Reading Lamp 49
Powertrain Control Module .65 Fog Lamp Illumination 45
Heater Blower Motor 64 4 WD Indicator Lamp 26, 53, 54
Heater, Engine Block .35 Full Time Indicator Lamp .53, 54
Heater System . 64 Glove Box Lamp .47
Blower Resistor . .64 Heated Rear Window Switch Lamp 45
Blower Switch .64 Heater A/C Panel Lamp .45, 47
Heater Blower Motor . -64 High Beam Indicator Lamp 55, 56, 57
Heat Mode Select Switch . . . . . . . . . . . . . . . . . . . . . .64 Indicator Lamp 4 WD .26, 53, 54
Heavy Duty Cooling 4.0L .23 Instrument Cluster Illumination Lamps 55, 56, 57
Fan Control Relay .23 Left Back-Up Lamp 87, 89
Powertrain Control Module .23 Left Courtesy Lamp 47
Radiator Fan Motor .23 Left Fog Lamp 37
High Beam Indicator Lamp 55, 56, 57 Left Headlamp 37
Hi-Line Instrument Cluster 57 Left Park/Turn Signal Lamp 37
Horn Brush/Slip Ring .32 Left Side Marker Lamp (Front) 37
Horn Relay • -32 Left Side Marker Lamp (Rear) 87, 89
Horn Switch .32 Left Tail/Stop Lamp , . .87, 89
Horns 32 Left Turn Indicator Lamp 55, 56, 57
Idle Air Control Motor . .15, 22 Left Turn Lamp (Amber) . . . . . . . . ... 87, 89
Ignition Key Warning Switch 70 Left Vanity Lamp .49
Ignition Switch .2, 9 License Lamp .87, 89
Ignition Switch System 9, 10 Low Washer Indicator Lamp .53, 54
Injectors .15, 22 Malfunction Indicator Lamp .53, 54
In Line Circuit Breaker .2, 74 Maintenance Required Indicator Lamp .53, 54
Instrument Cluster .51 Park Brake Indicator Lamp . .54
Powertrain Control Module 51 Beading Lamp 49
Washer Fluid Level Switch 51 Rear Wiper/Wash Switch Lamp 45
Instrument Cluster (Hi-Line) -57 Right Back-Up Lamp . .88, 90
Instrument Cluster (Lo-Line) • 56 Right Courtesy Lamp .47
Instrument Cluster (Standard) .55 Right Fog Lamp 38
Instrument Cluster Connector . . . . . . . . . . . . . . . . . . . .102 Right Headlamp 38
Instrument Cluster Connector 16 Way 5 1 , 102 Right Park/Turn Signal Lamp 38
Instrument Cluster Indicator Printed Circuit Board (W/ABS) .53 Right Side Marker Lamp (Front) .38
Instrument Cluster Indicator Printed Circuit Board Right Side Marker Lamp (Rear) 88, 90
(W/0 ABS) 54 Right Tail/Stop Lamp 88, 90
Instrument Cluster Indicators 52 Right Turn Indicator Lamp .55, 56, 57
Right Turn Lamp (Amber) . . .88, 90 Radiator Fan Motor . 23
Right Vanity Lamp 49 Rear Wiper Motor 61
Seat Belt Indicator Lamp .53, 54 Right Front Door Lock Motor .82
Transfer Case Lamp .46 Right Front Door Window Motor . 77
Transmission Range Switch Lamp 46 Right Power Mirror 69
Underhood Lamp .32 Right Rear Door Lock Motor 82
Upshift Indicator Lamp 53, 54 Right Rear Door Window Motor .78
Vanity Lamps 49 Oil Pressure Switch (Engine) .24
L.C.D. Illumination Relay 50 Park Brake Switch 63
Left Front Door Connector and Door Lock Switch Park Brake Indicator Lamp .54
Function Chart 83 Parking Brake Switch 63
Left Front Door Connector and Window Lift Switch Pedal Travel Sensor 28
Function Chart 83 Power Distribution Center . 1 , 2, 3, 4
Left Front Door Jamb Switch 71 Power Distribution Center Application Chart 4
Left Front Door Lock Motor 82 Power Distribution Center Identification . . . . . . . . . . . . . . .3
Left Rear Door Window Connector and Window Lift Power Door Locks 79, 80, 8 1 , 82
Function Chart .84 Keyless Entry Module . . .79
Left Front Wheel Sensor . . 27 Left Front Door Lock Motor 82
Left Rear Door Window Connector and Window Lift Left Rear Door Lock Motor 82
Switch Function Chart 84 Left Door Lock Switch .81
Left Rear Door Jamb Switch 71 Liftgate Lock Motor .82
Left Rear Door Window Switch 78 Power Door Lock Relay .79
Left Power Seat Motor Assembly 73 Power Door Unlock Relay 79
Left Rear Wheel Sensor 27 Right Door Lock Switch 81
Left Turn Relay 91 Right Front Door Lock Motor 82
Liftgate Switch 72 Right Rear Door Lock Motor .82
Liftgate Lock Motor . . . . . . . . .82 Power Door Lock Relay 79
Lo-Line Instrument Cluster Printed Circuit Board 56 Power Door Unlock Relay .79
Low Washer Indicator Lamp .53, 54 Power Mirror Connector 104
Malfunction Indicator Lamp 53, 54 Power Mirror Connector and Switch Function Chart 84
Main Body Connectors .106 Power Mirror Switch Assembly .69
Maintenance Required Indicator Lamp 53, 54 Power Mirror System 69
MAP Sensor 14, 19 Left Power Mirror . 69
Master Window Switch .75 Power Mirror Switch Assembly 69
Modules Right Power Mirror • .69
Anti-Lock Brake System Module . . . . . .27, 28, 29, 30, 31 Power Mirrors 69
Chime Module 70 Power Seats 73, 74
Daytime Running Lamp Module .36 Left Power Seat Motor Assembly .73
Headlamp Delay Module 41 Left Power Seat Switch 73
Intermittent Wiper Module 60 Power Steering Pressure Switch .15
Keyless Entry Module .79 Powertrain Control Module 1 1 , 12, 13, 14, 15, 16, 17,
Powertrain Control Module . . . 1 1 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 2 1 , 22, 23, 33, 34, 43, 5 1 , 65
18, 19, 20, 2 1 , 22, 23, 33, 43, 5 1 , 65 Powertrain Control Module (PCM) Connector 105
Transmission Control Module 25, 26 Power Windows 75, 76, 77, 78
Motors Left Front Door Window Motor 77
ABS Pump Motor . 28 Left Rear Door Window Motor .78
A/C Heater Blower Motor 66 Left Rear Door Window Switch 78
Engine Starter Motor . . . . . . . . . . . . . . . . . . . . . . .7, 8
Master Window Switch .75
Front Wiper Motor .59, 60
Power Window Switch .75
Heater Blower Motor 64
Right Front Door Window Switch . . 77
Idle Air Control Motor 15, 22
Right Front Door Window Motor .77
Left Front Door Lock Motor 82
Right Rear Door Window Motor . . . . . . . . . . . . . . . . .78
Left Front Door Window Motor .77
Right Rear Door Window Switch 78
Left Power Mirror 69
Power Window Switch 75
Left Power Seat Motor Assembly .73
Pumps
Left Rear Door Lock Motor 82
Front Washer . .59, 60
Left Rear Door Window Motor 78
Rear Washer .61
Liftgate Lock Motor 82
Radiator Fan Motor . .23
Radio .67 Right Rear Door Window Connector and Window Lift
Radio (4 Speaker System) 67, 68 Switch Function Chart 83
Antenna Mast 67 Right Front Door Window Connector and Window Lift
Switch Function Chart 83
Left Front Door Speaker 67
Right Rear Door Jamb Switch 72
Left Instrument Panel Speaker .67
Right Rear Door Window Connector and Window Lift
Left Liftgate Speaker .68
Function Chart . .84
Right Front Door Speaker . .68
Right Rear Wheel Sensor .27
Right Instrument Panel Speaker .68
Right Turn Relay 91
Right Liftgate Speaker . .68
Seat Belt Switch 70
Reading Lamps .49
Seat Belt Indicator Lamp 53, 54
Rear Lighting .87, 88, 89, 90
Sensors
Left Back-Up Lamp . 87, 89
Camshaft Position Sensor 1 1 , 20
Left Side Marker Lamp (Rear) 87, 89
Crankshaft Position Sensor 1 1 , 20
Left Tail/Stop Lamp .87, 89
Engine Coolant Temperature Sensor 14, 19
Left Turn Lamp (Amber) 87, 89
G Sensor .28
License Lamp .87, 89
Heated Oxygen Sensor 13, 21
Right Back-Up Lamp 88, 90
Intake Air Temperature Sensor 14, 19
Right Side Marker Lamp (Rear) 88, 90
Left Front Wheel Sensor . .27
Right Tail/Stop Lamp .88, 90
Left Rear Wheel Sensor 27
Right Turn Lamp (Amber) 88, 90
MAP Sensor 14, 19
Rear Lighting with Trailer Tow 89, 90
Pedal Travel Sensor 28
Rear Lighting without Trailer Tow . .87, 88
Right Front Wheel Sensor 27
Rear Washer Pump 61
Right Rear Wheel Sensor 27
Rear Wiper Motor 61
Throttle Position (Sensor) . 14, 19
Rear Wiper/Washer • • .61
Vehicle Speed Sensor 1 1 , 20
Rear Washer Pump .61
Speakers 67, 68
Rear Wiper Motor .61
Left Front Door Speaker 67
Rear Wiper/Washer Switch .61
Left Instrument Panel Speaker 67
Reed Switch 26
Left Liftgate Speaker . .68
Relays
Right Front Door Speaker 68
ABS # 1 Relay . . . . . . . 3, 29
Right Instrument Panel Speaker 68
ABS # 2 Relay .3, 29
Right Liftgate Speaker 68
A/C Compressor Clutch Relay .3, 65
Splices
Automatic Shut Down Relay .3, 12, 17
Splice A3 . 1 , 39
Ballast Resistor Relay By-Pass 85
Splice A11 . .5, 6
Cooling Fan Relay 3
Splice A11-1 74, 91
Engine Starter Relay 3, 7, 8
Splice A14 12, 17
Fan Control Relay 23
Splice A21 . . .2, 12, 17
Fog Lamp Relay 37
Splice A21-1 .2, 10
Fuel Pump Relay 3, 12, 17
Splice A38 2, 10
Heated Rear Window Relay .62
Splice A142 15, 22
Horn Relay .32
Splice A142-1 15, 22
L.C.D. Illumination Relay .52
Splice A142-2 5, 6, 15, 16, 18, 22
Left Turn Relay 91
Splice C7 .66
Power Door Lock Relay 79
Splice C15 . 62
Power Door Unlock Relay 79
Splice C43 64, 66
Right Turn Relay 91
Splice C90 .65
Stop Lamp Relay 91
Splice E2 .45
Relay Center Identification 107
Splice F12 . . . . . . . . . .16, 18, 65
Resistor, Ballast 85
Splice F34 . .39
Resistor, Blower 64, 66
Splice F85 . 35, 67
Right Front Door Jamb Switch .72
Splice G7 1 1 , 20
Right Front Door Window Switch 77
Splice K4 14, 19
Right Front Wheel Sensor 27
Splice K4-1 . 14, 19
Right Front Door Connector and Door Lock Switch
Splice K6 . . . . .14, 19
Function Chart 83
Splice K7 1 1 , 20
Right Front Door Lock Motor .82
Splice K22 . 19
Splice K29 .44 Left Door Lock Switch .81
Splice L90 . . .87, 89 Left Front Door Jamb Switch 71
Splice L90-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Left Front Door Window Switch 77
Splice L90-2 88, 90 Left Power Seat Switch 73
Splice L90-3 87, 89 Left Rear Door Jamb Switch 71
Splice M1 • . .51 Left Rear Door Window Switch 78
Splice M1-1 47 Liftgate Switch 72
Splice M2 48 Master Window Switch 75
Splice M2-1 . . . . . . 47 Park Brake Switch 63
Splice Q1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Power Mirror Switch Assembly 69
Splice P2 82 Power Steering Pressure Switch 15
Splice P34 82 Power Window Switch .75
Splice Z0 5 Rear Wiper/Washer Switch 61
Splice Z1 .51 Reed Switch .26
Splice Z1-1 42, 91 Right Door Lock Switch 81
Splice Z1-2 . . . 40 Right Front Door Jamb Switch 72
Splice Z1-3 58 Right Front Window Switch . .77
Splice Z1-4 59, 60 Right Rear Door Jamb Switch .72
Splice Z1-5 42, 62 Right Rear Window Switch 78
Splice Z1-6 87, 89 Seat Belt Switch 70
Splice Z1-7 .88, 90 Stop Lamp Switch ......... 44
Splice Z1-10 .38 Transmission Range Switch . . . . . . . . . . . . . . . . . . . 25
Splice Z1-11 . . . .31 Turn/Hazard Flasher Switch 44
Splice Z1-12 • . .32 Vehicle Speed Control Switch 33
Splice Z1-13 .69 Washer Fluid Level Switch 53
Splice Z11 • .16, 18 Wiper/Washer Switch 59, 60
Splice Z12 .29 Telltale Connector . 52, 101
Splice Z12-1 . 13, 21 Trailer Tow . 9 1 , 92
Splice 117 . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Left Turn Relay 91
Splice 205 30 Right Turn Relay . 91
Splice 235 . .31 Stop Lamp Relay • • 91
Steering Column Connector 11 Way 100 Trailer Tow In-Line Circuit Breaker .91
Stop Lamp Relay 91 Transmission Range Switch . f .25
Stop/Turn and Hazard Systems 43, 44 Transfer Case Lamp 46
Hazard Flasher . 44 Transmission Control Magnetic Trigger Wheel 26
Hazard Switch . .44 Transmission Control System .25, 26
Powertrain Control Module . .43 Back-Up Lamp Switch .25
Stop Lamp Switch 44 Front Axle Lock-Up Switch .26
Turn and Hazard Flasher Switch . . 44 Dat| Link Connector 25
Turn Signal Flasher 43 Indicator Lamp 4 WD 26
Switches Throttle Position (Sensor) 14, 19
A/C Low Pressure Switch . .65 Transmission Control Magnetic Trigger Wheel 26
A/C Mode Select Switch . 66 Transmission Control Module 25, 26
Back-Up Lamp Switch . 25 Transmission Range Switch 25
Blower Switch 64, 66 Turn Signal Flasher .43, 93
Brake Warning Switch . .63 Turn/Hazard Switch Assembly 44
Engine Coolant Temperature Switch 24 Transmission Control Unit (TCM) Connector 99
Engine Oil Pressure Switch 24 Underhood Lamp .32
Fog Lamp Switch 40 Upshift Indicator Lamp . . . . . . . . . . . . . . . . . . . . . .53, 54
Front Axle Lock-Up Switch . . . . . . . 26 Underhood Lamp/Horn System . . . . . . . . . . . . . . . . . . . .32
Hazard Switch 44 Horn Relay 32
Headlamp Dimmer Switch 39 Horn Brush/Slip Ring 32
Headlamp Switch . 1 , 39 Horn Switch 32
Heat Mode Select Switch 64 Horn Left Side .32
Heated Rear Window Switch . .62 Horn Right Side 32
Horn Switch .32 Underhood Lamp .32
Ignition Key Warning Switch 70 Vanity Lamps 49
Ignition Switch .2, 9 Vehicle Speed Control Sensor . 1 1 , 20
Vehicle Speed Control Servo 34 Wall Plug, Engine Block Heater 35
Vehicle Speed Control System 33, 34 Washer Fluid Level Switch 51
Hazard Flasher 33 Windshield Wiper Circuit Breaker 2, 59
Powertrain Control Module 33, 34 Wiper/Washer Switch 59, 60
Vehicle Speed Control Servo 34 Windshield Wiper System (Standard) 59
Vehicle Speed Control Switch 33 Windshield Wiper System (Intermittent) .60
Al 10R0
CENTER
( S E E SH 4)
A7
12RD
YL*
BATTERY A3
12RD FUSE # 1 1
A6 12RD/DB* WT* 25 AMP
O (WHITE)
11
1
A4 12BK/RD* —
FUSE #18
25 AMP
A3 X4
(WHITE)
12RD 16GY
f l FUSE # 9
WT* OR*
10 AMP 18k
(RED) •A3 12RD/0R * — 1
X
HEADLAMP
DELAY MODULE
FUSE # 1 5 SH 41
15 AMP HORN R E L A Y
F81
(LIGHT BLUE)
15S SH 32
12BR
DOME LAMP
x
HEATED
L7 18BK/0R*
HEADLAMP
SWITCH
SH 49 REAR SH 39
GLOVE BOX WINDOW
LAMP RELAY L7 18BK/YL * -
SH 47 E2
SH 62
COURTESY 200R
LAMPS BK*
SH 47 CHIME FUSE #19
TELLTALE
CONNECTOR
MODULE
SH 70
5 AMP
(TAN) 19
6
SH 52
RADIO
SH 67
5
CARGO
LAMP E2 200R/DG*
SH 48 P FUSE # 4
15 AMP X
5 (LIGHT BLUE)
H E A T E R A/C
PANEL LAMP
T R A N S F E R CASE
LAMP
SH 45 SH 46
H E A T E D REAR TRANSMISSION
WINDOW RAN6E
S W I T C H LAMP S W I T C H LAMP
Lll
SH 45 SH 46
16PK
REAR INSTRUMENT
LG* CLUSTER
WIPER/WASHER
SWITCH SH 51
1
HEADLAMP
LAMP
SH 45
FOG LAMP
LCD
ILLUMINATION
RELAY
ILLUMINATION SH 50
DIMMER S W I T C H SH 45 RADIO
SH 3 9 ASH T R A Y SH 67
LAMP
SH 4 6
CI6AR L I 6 H T E R
LAMP
SH 4 6
XJ 1 FUSE APPLICATION CHART J938W-3

POWER DISTRIBUTION
CENTER
( S E E SH 4)
•A38 120R
FUSE # 1
^ 25 AMP
Q (WHITE)
I
V15 236
18LB 18L6
RD* YL*
i
REAR
ANTI-LOCK
BRAKE S Y S T E M
WIPER/WASHER
MODULE
SWITCH
SH 30
SH 61
F87 INSTRUMENT
FUSE #2 CLUSTER
FUSE # 5 FUSE # 8 20WT
15 AMP SH 51
25 AMP 20 AMP BK*
(LIGHT
(WHITE) (YELLOW)
BLUE)
CHIME
MODULE DAYTIME
SH 70 RUNNIN6
LAMP
MODULE
IN L I N E SH 36
F85 C7 CIRCUIT F U E L PUMP
18VT 12BK BREAKER RELAY
WT* TN* 4.8 AMP SH 12,17
LCD
JL
ILLUMINATION
i
H E A T E R AND
TURN
AUTOMATIC
S H U T DOWN
SH
RELAY
12,17
RELAY SI6NAL
A/C MODE POWERTRAIN
SH 50 FLASHER F86
SELECTOR CONTROL
RADIO SH 43 18L6
SWITCH MODULE
SH 67 SH 6 4 , 6 6 FRONT BK*
CIGAR L I G H T E R WIPER SH 12.17
SH 35 MOTOR j,
H E A T E D REAR SH 5 9 , 6 0
WINDOW WIPER/WASHER
RELAY SWITCH
SH 62 SH 5 9 , 6 0
J938W-3 FUSE APPLICATION CHART XJ 2

TO P O S I T I V E
B A T T E R Y CABLE
( S E E SH 7 , 8 )
B U S S BAR FEED
AO
RELAY G 6RD
ABS ^ 1
4 . 0 L ONLY F16 (60 AMP)
( S E E SH 2 9 )
F15 (30 AMP)
RELAY F
ENGINE S T A R T E R
( S E E SH 7 , 8 )
RELAY E
AUTOMATIC
S H U T DOWN
( S E E SH 1 2 , 1 7 )
RELAY D
A/C COMPRESSOR
CLUTCH
( S E E SH 6 5 )
F8 (60 AMP)
RELAY C
ABS # 2
4 . 0 L ONLY
( S E E SH 2 9 ) F7 (30 AMP)
RELAY B
F U E L PUMP
( S E E SH 1 2 , 1 7 )
F6 (15 AMP)
F3 (10 AMP)
F5 (15 AMP)
RELAY A
C 0 0 L I N 6 FAN F2 (15 AMP)
4 . 0 L ONLY
( S E E SH 2 3 ) F4 (20 AMP)
Fl (20 AMP)
XJ 3 CENTER I D E N T I F I C A T I O N J938W-3
WIRING DIAGRAMS SW - 141
FUSE # 9
( 1 0 AMP) TO FAN CONTROL TO AUTOMATIC TO T R A N S M I S S I O N S\
RELAY S H U T DOWN R E L A Y CONTROL MODULE TO < F 1 2 > S P L I CE
( S E E SH 23) ( S E E SH 1 2 . 1 7 ) ( S E E SH 2 5 ) \Z
TO ( S E E SH 1 6 . 1 8 )
UNDERHOOD
TO < M 1 > 1 [ S P L I C E
( S E E SH 47)
FUSE
Fl
20 AMP
7.8)
TO
FRONT END
LIGHTING
SYSTEM
( S E E SH 3 8 )
A3 TFEED
12RD F39
WT* 18PK
OfEED F 3 9 \ L6X
18PK
TO D A Y T I M E
FEEDf LGX
RUNNIN6
LAMP MODULE , , JFEED
TO HAZARD
( S E E SH 36) ( S E E SH 5 , 6 ) DATA L I N K CONNECTOR
FLASHER
( S E E SH 3 3 ) ( S E E SH 2 5 . 3 0 )
POWER DISTRIBUTION CENTER
J938W-3 APPLICATION CHART XJ
c c c n TO POWERTRAIN
F E E D
„ n A r CONTROL MODULE
K20 18DG J C A V I T Y 20
( S E E SH 13)
FEED TO < M 4 2 > 1 [ S P L I C E

•A142 18DG/0RX-
( S E E SH 15)
FEED TO POWER
DARK GRAY All 1ORK/WT * ( DISTRIBUTION
(NEAR GENERATOR) All 10BK/WT*—) C E N T E R F U S E F 8
( S E E SH 4)
TO POWER
FEED
, DISTRIBUTION
All 10BK/WTX—5 CENTER F U S E F 1 6
( S E E SH 4)
A142 18DG/0R*~-i>T~
L
K20 1 8 D G — E p L -
BLACK-
A142
16DG
OR*
C
K20 18DG- •<f
6ENERAT0R
A142
HD/LP 16DG
DASH OR*
ENG
FEED
TO D I S T R I B U T O R
IGNITION
COIL
( S E E SH 16) (RIGHT S I D E
REAR OF E N G I N E )
ENGINE | ^ > -ZO 4BK 7 A .oi^ i ' 0 BA1 I t K Y

GROUND ZO 4BK \ ( S E E SH 7)
ENG
zo;
XJ 5 CHARGING SYSTEM 2.5L ENGINE JS38W-3

TO P O W E R T R A I N
FEED „ CONTROL MODULE
•K40 18DG — \ C A V I T Y 20
( S E E SH 2 0 )
FEED TO < A 1 4 2 > I SPLICE

A142 18DG/0R*
(SEE SH 22)
HD/LP
DASH
DARK GRAY FEED TO POWER
(NEAR GENERATOR) DISTRIBUTION
All 10BK/WTX ^
CENTER F U S E F8
( S E E SH 4)
FEED TO POWER
All 10BK/WTX- DISTRIBUTION
CENTER F U S E F 1 6
All ( S E E SH 4)
8BK
BLACK
WT*
c
ZO 8BK-
B
A142 18DG/0R*H<br~
A142 K20 18DG—
16DG
OR* BLACK
GENERATOR
A142
16DG
OR*
TO
DISTRIBUTOR
IGNITION
COIL ( R I G H T REAR
OF E N G I N E )
( S E E SH 18)
ENGINE I (oÔ- ZO 8BK-
GROUND TZL-
J938W-3 CHARGING SYSTEM 4.OL ENGINE XJ 6

8W 144 WIRING DIAGRAMS 4
FEED TO POWER
AO 6RD D I S T R I B U T I O N CENTER
( S E E SH 4 )
FEED TO POWER
-A4 14BK/RD*- D I S T R I B U T I O N CENTER
FUSE F5
( S E E SH 4)
FEED €
TO POWER
•A4 14BK/RDX — — J D I S T R I B U T I O N CENTER
FUSE FIO
( S E E SH 4)
TO
FEED. IGNITION
-A41 1 4 Y L - A41 14YL ) SWITCH
( S E E SH 9)
H?
SPLICE ENGINE
( S E E SH 5 ) STARTER
RELAY
( I N POWER
Z12 18BK/TN*!
DISTRIBUTION
CENTER) T 4 0 12BR
S E E SH 3 )
30- A41 1 4 Y L
-A4 14BK/RDX
-A4 14BK/RD*
i .. . ——-i
BODY T40
TO
GROUND 12BR
(RIGHT GND .<Z12>1|
SIDE Z12 18BK/TN %
FENDER
SPLICE
SHIELD)
.RIGHT SIDE ( S E E S H 13)
FENDER S H I E L D )
AO BLACK
4RD
XJ 7 2.5L ENGINE S T A R T E R SYSTEM J938W-3

FEED TO POWER
AO 6RD — f D I S T R I B U T I O N CENTER
* ( S E E SH 4 )
FEED TO POWER
-A4 1 4 B K / R D X - — ( D I S T R I B U T I O N CENTER
' FnUir-r
S E F5re
( S E E SH 4 )
F F F D TO POWER
-A4 14BK/RDX -——^ DI STRI^BJjnO^N ^CENTER
(SEE SH 4 )
TO
FEED IGNITION
•A41 14YL \ SWITCH
( S E E SH 9)
ENGINE
ENGINE STARTER
GROUND RELAY T41 1 8 B R / Y L * ( A U T O T R A N S ONLY)
(RIGHT ( I N POWER T41 1 8 B R / Y L * ( A U T O T R A N S ONLY)
REAR DISTRIBUTION
Z12 18BK/TN*(MANUAL T R A N S ONLY)|
OF CENTER)
( S E E SH 3) T 4 0 12BR
ENGINE)
A41 1 4 Y L
A4 1 4 B K / R D X
AO A4 J j B K / R D £
BODY
GROUND 4RD
(RIGHT G N D . CONTROL MODULE
SIDE (LEFT 5 C A V I T Y 30
FENDER SIDE ( S E E SH 2 1 )
SHIELD) FENDER
SHIELD)
GND , TO T R A N S M I S S I O N
T41 18BR/YLX- —A CONTROL S Y S T E M
( S E E SH 25)
TO
GNO :zi2>ii
Z12 18BK/TN X •
SPLICE
( S E E SH 21)
MANUAL TRANSMISSION ONLY-
ENGINE
STARTER
MOTOR
i . .—i
J938H-3 4 . 0 L ENGINE S T A R T E R SYSTEM XJ 8

E4
TO POWER
FEED
r DISTRIBUTION
•Al 10RD i CENTER F U S E F l l
( S E E SH 4)
Al
12RD
IGNITION
SWITCH
ACC#- OFF N H2
RUN
FEED TO ENGINE
Al A41 14YL——{ S T A R T E R RELAY
STARTS -»—A41 14YL
12RD >
( S E E SH 7 , 8 )
/RUN
-»—A38 120R A38 120R—
START
TO
ACC#^ FEED
S T A R T S " RUN
ACC#- OFF N
»-A48 12VT
7*
F85 \y
SPLICE
( S E E SH 3 5 )
—^ ^RUN
FUSE # 2
( 1 5 AMP)
STARTS- -)> A21 12DB A21 12DB-

ACC#- OFF N
TO * 4
PARK BRAKE p E E D
RUN
START # ^
6 9 2 0 G Y / W T
SYSTEM $ *"^<-
( S E E SH 6 3 ) ACC#- OFF N
START j»RUN
6R0UND T H R U
620 S T E E R I N 6 COLUMN
20VT \
\ = ATTACHMENT
YL* \
>-620 20VT/YL*-.
\
FEED
-A 620 20VT/YL*
-69 206Y/WT* -A41 1 4 Y L

620 20VT/YL*! - A l 12RD TO
BLACK BLUE EN6INE
COOLANT
12RD TEMPERATURE
A48 12VT TO SENDER
INSTRUMENT ( S E E SH 2 4 )
A21 12DB
CLUSTER
A38 120R
( S E E SH 5 1 )
i i
[CONNECTORS LOCATED AT B A S E OF
S T E E R I N 6 COLUMN)
XJ 9 IGNITION SYSTEM J938W-3

FEED TO A N T I - L O C K
f BRAKE S Y S T E M
>
( S E E SH 30)
FUSE # 1
( 2 5 AMP)
« F n TO REAR
MIP
-)) VIS 1 8 L B / R D * ^ |(?JP
(SEE SH 6 1 )
A38
120R
WT*
A38 120R
A38
120R
TO INSTRUMENT
INST/ FUSE # 1 7 CLUSTER
66 ( 7 . 5 AMP)
PNL ( S E E SH 5 1 )
TFEED
A21 12DB )r—F87 18WT/BK*-
^-F87 20WT/BK*-
4.0L
ONLY FEED
12DB
12DB
YL* TO CHIME
MODULE
( S E E SH 70)
B6
A21
12DB
FEED
TO
SPLICE
( S E E SH 1 2 , 1 7 )
J938W-3 I G N I T I O N SYSTEM X J 10
BLACK
K7 180R
TO I N S T R U M E N T
CLUSTER K4 18BK/LB*r -»
(LEFT SIDE
( S E E SH 5 1 )
KICK PANEL) G7 18WT/0R*!
VSS
18WT/0R*-
G7 20WT/OR* G7 20WT/0R *
BLACK (RIGHT
K7 180R SIDE
K4 1 8 B K / L B * DASH
K44 1 8 T N / Y L * PANEL)
VEHICLE
SPEED
SENSOR
BLACK (MOUNTED
K7 180R ON
K24 1 8 G Y / B K * K4 18BK/LB * TRANSMISSION)
K4 1 8 B K / L B *
I—K7 180R
•K7 180R
TO D A Y T I M E
RUNNING LAMP
MODULE
( S E E SH 36)
CRANKSHAFT FEED
POSITION
SENSOR
(LEFT SIDE
REAR OF
ENGINE)
SPLICE
( S E E S H 14)
CAMSHAFT
POSITION
SENSOR HD/LP
IN DISTRIBUTOR) DASH
K24 K44
K7
18GY 18TN
180R
BK* YL*
24 7 44 47
DIST PICK-UP 8 VOLT CAMSHAFT SENSOR VEHICLE
SI6NAL B + SUPPLY PICK-UP SPEED
SENSOR
INPUT
P O W E R T R A I N CONTROL MODULE
( F R O N T L E F T OF E N 6 I N E COMPARTMENT)
(CONNECTOR S E E S H 1 0 5 )
FUEL INJECTION IGNITION

X J 11 SYSTEM (2.5L ENGINE) J938W-3
4 WIRING DIAGRAMS 8W * 149
TO POWER
FEED DISTRIBUTION
X CENTER
}
FUSE F15
( S E E SH 4)
( F R O N T L E F T OF E N G I N E COMPARTMENT)
(CONNECTOR S E E SH 105)

J938W-3 SYSTEM (2.5L ENGINE) XJ 12
TO POWER
STEERING PRESSURE
SWITCH HD/LP
( S E E SH 15) DASH
GND
Z12 18BK/TN *
TO ENGINE STARTER
Z12 Z12
(SEE SH 7) 5 212 18BK/TN X
I6BK 16BK
GND TNX TNX
D A Y T I M E RUNNING
LAMP MODULE
( S E E SH 3 6 )
Z12 18BK/TN X
Z12 18BK/TN X-
1 ENGINE
K41 GROUND
, 18BK (RIGHT
K4 DGX S I D E OF
K41
18BK_, ENGINE)
18BK
DGX LBX
HEATED
OXYGEN
SENSOR
(LEFT SIDE
OF ENGINE I N
EXHAUST P I P E )
FEED
TO
TO CHARGING S Y S T E M
BALLAST
( S E E SH 5 )
BY-PASS 5"
RELAY FEED
( S E E SH 8 5 )
K41 K37 Z12 Z12
K20
18BK 20RD 16BK 16BK
DGX 18DG TNX
DBX TN*
i i X 1
41 37 20 11 12
HEATED BY-PASS V0LTA6E PWR PWR
0XY6EN RELAY REGULATOR GRND GRND
SENSOR
INPUT P O W E R T R A I N CONTROL MODULE
( S E E SH 1 0 5 )
F U E L INJECTION I G N I T I O N
XJ 13 SYSTEM ( 2 . 5 L ENGINE) J938W-3
K4 18BK/LB* xzsi
TO
Kl 20DG/RD*
CAMSHAFT P O S I T I O N
SENSOR f K6 2 0 V T / W T *
( S E E SH 11) ) -K4 18BK/LB *
BLACK
GND
TO
VEHICLE SPEED MAP SENSOR
SENSOR F GND (REAR C E N T E R
( S E E SH 1 1 ) 1
r -— K4 18BK/LB * \ OF ENGINE
\ COMPARTMENT)
THROTTLE
P O S I T I O N (SENSOR)
(ON T H R O T T L E BODY)
ENGINE INTAKE
COOLANT T E M P E R A T U R E AIR TEMPERATURE
SENSOR (ON SENSOR (NEAR
T H E R M O S T A T HOUSING) T H R O T T L E BODY)
-»-
K4
18BK K21 K4 K4
K6 K22 K4 18BK
1 R
LB* 18BK 18BK
20VT ?2 18BK RD* LB* LB*
WT*
D B
* LB*
Kl K6
(NEAR 20DG 20VT
BLACK THROTTLE WT*
R D
BEHIND BODY) TO *
L E F T HAND CRANKSHAFT
(NEAR
ENGINE BLACK POSITION
THROTTLE
BODY) MOUNT) SENSOR
( S E E SH
11)
K6 K22 K4
20VT 180R 18BK
WT* DB* LB* HD/LP
DASH
HD/LP
DASH
K22 K2 K4 K21 Kl K6
180R 20TN 18BK 18BK 20DG 20VT
DB* BK* LB* RD* TO H E A T E D OXYGEN RD* WT*
22
T.P.(S)
2
JL
ECT
J J
JL
4
GROUND
i
21
INTAKE
AIR TEMP.
SENSOR
( S E E SH 13)
i _
1
MAP
6
5 VOLT
INPUT SENSOR I N P U T SENSOR SUPPLY
SENSOR I N P U T
POWERTRAIN CONTROL MODULE
(FRONT LEFT OF ENGINE COMPARTMENT) (CONNECTOR S E E SH 105)

J938W-3 SYSTEM ( 2 . 5 L ENGINE) XJ 14
J
TO GENERATOR GND BLACK
-A142 18D6/0R *
( S E E SH 5 )
TO D I S T R I B U T O R ' GND
I G N I T I O N COIL V—— -A142 16D6/0R* A142 16D6/0R * AM2 18DG/0R*
( S E E S H 16)
(RI6HT SIDE
IDLE AIR
SHIELD)
CONTROL MOTOR
BLACK
K59 18VT/BK *
K39 186Y/RD*
K60 18YL/BK* K39 186Y/RD *
K40 18BR/WT*
K59 18VT/BK* K60 18YL/BK * •
K40 18BR/WT *
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4

BLACK BLACK-j BLACK BLACK
4 A142
18DG
G3 (ON I N T A K E
MANIFOLD)
OR*
Kll A142 A142 K13 A142 K14 A142

K12
18WT 18D6 18DG 18YL 18DG 18LB 18DG
18TN
DB* OR* OR* WT* OR* BR* OR*
s^=l i£ih x£i

FEED
TO A U T O M A T I C S -
S H U T DOWN H n / | p
H D L P
RELAY /n c u
i
D A S H
( S E E S H 12) A142
14DG
UaH2^ OR*
A142 18DG/0R*
A142 18DG/0R*
A142 18DG/0R*
A142 18DG/0R*
KIO 18DB/WT*
GRAY HD/LP
Z12 18BK/TN* OASH
POWER S T E E R I N G
P R E S S U R E SWITCH
\ (ON POWER S T E E R I N G
* PUMP)
1>
Kll K13 K14 Z12 KIO A142 K40 K60 K39 K59
K12 18BK
18WT 18YL 18LB 18DB 18DG 18BR 18YL 18GY 18VT
18TN TN*
DB* WT* BR* WT* OR* WT* BK* RD* BK*
t
,16
+IS
INJECTORS
tI
14
GND
JO<^Z122ll SPLICE
(SEE SH 13)
10
P.S
_1_
JL JL
JL57
AUTO
L
40
i _
60
39
I.A.C.MOTOR
59
SWITCH SHUT
DOWN
SENSE
(FRONT LEFT OF E N G I N E COMPARTMENT)(CONNECTOR S E E S H 105)
TO POWER FEED
FEED I TO 6 E N E R A T 0 R
DISTRIBUTION r 3
( S E E SH 5)
F12 18DB/WT*
CENTER F U S E F 6 >
( S E E SH 4 )
TO WASHER
FEED BLACK
FLUID LEVEL
SWITCH y— F12 18DB/WT* K19 18BK/6Y*i
( S E E SH 5 1 )
•A142 16DG/0R*!
TO B A L L A S T
RESISTOR FEED
BY-PASS
RELAY 5 F12 18DB/WT %
( S E E SH 8 5 )
TO A/C
COMPRESSOR FEED
CLUTCH
RELAY 5 F12 18DB/WT*
( S E E SH 6 5 )
DISTRIBUTOR
IGNITION
TO B A C K - U P FEED COIL
LAMP S W I T C H V F12 18DB/WT*
( S E E SH 2 5 )
TO
VEHICLE FEED
SPEED ) F12 18DB/WT X
CONTROL
( S E E SH 3 3 )
D20 20LG-
L6JI 5 H— F 1 2 18DB/WT*
mm
DATA L I N K
CONNECTOR
(LEFT SIDE
0v
I
BLACK
SHIELD)
BLACK
(NEAR C O I L )
021 D20 K19

20PK 20L6 18GY
EN6INE
GROUND
( R I 6 H T REAR
OF E N G I N E )
5 25 45. 19
SIGNAL DATA LINK COIL DRIVER
6R0UND #1
( F R O N T L E F T OF E N 6 I N E COMPARTMENT)
(CONNECTOR S E E SH 1 0 5 )

J938W-3 SYSTEM (2.5L ENGINE) XJ 16
TO
A141 H D G / B K *
A21>1 TO POWER
-A142 18DG/0R* A M I H D G / B K *
DISTRIBUTION
m ni ^ i j — A 2 i i 2DB SPLICE
(SEE SH 10)
CENTER
(SEE
FUSE
SH 4)
F6
5 E r -
A21 12DB
A18 18RD/BK* " T F E E D A H H R D

A21
K51 2 0 D B / Y L * K51 2 0 D B / Y L *
12DB
•K51 2 0 D B / Y L *
u
FEED TO DAYTIME RUNNING
2
A* f L( A
SM P
EE SMHO D U3 L6 E)
12DB >
A21 12DB
FUSE F2
(LOCATED IN
POWER
DISTRIBUTION A21
CENTER) 12DB
A H H R D
A14
H R D AUTOMATIC SHUT FUEL PUMP
DOWN RELAY RELAY
(LOCATED IN (LOCATED IN
POWER DISTRIBUTION POWER DISTRIBUTION
CENTER CENTER
SEE SH 3) SEE SH 3)
A141 A141 K51

2 0 D B
HOG HDG
Y L
B K * B K * *
TO <A142>T1 SPLICE
(SEE SH 22)
TO BALLAST FEED
FEED
RESISTOR
(SEE SH 85)
TO BALLAST
RESISTOR BY-PASS
NO
RELAY
CONNECTION
(SEE SH 85)
F6
FEED TO TRANSMISSION
•A14 H R D A H H R D ( CONTROL MODULE
(SEE SH 26)
AUTOMATIC
TRANSMISSION TO POWER
KIO DISTRIBUTION
FEED
18VT A H H R D CENTER
FUSE F 1 5
(SEE SH 4)
i 51
10 9 3
SI6NAL GROUND IGN A.S.D.

(FRONT L E F T OF ENGINE COMPARTMENT)

XJ 17 SYSTEM (4.0L ENGINE) J938W-3
TO POWER FEED
DISTRIBUTION FEED
CENTER F U S E F 6 5 F12 18DB/WT* Jf TO 6 E N E R A T 0 R
1
( S E E SH 4) ( S E E SH 6 )
TO WASHER FEED A142

FLUID 16D6
L E V E L SWITCH
( S E E SH 5 1 )
5 F12
18DB/WT* EN6 OR*
TO B A L L A S T FEED
RESISTOR
BY-PASS RELAY 5 F12 18DB/WT*
( S E E SH 85)
TO FAN /EH)
CONTROL R E L A Y r — F12 18DB/WT X
( S E E SH 23)
TO A/C MANUAL
COMPRESSOR FEED TRANSMISSION
CLUTCH
( S E E SH 6 5 ) 5 F12
18DB/WTX ONLY
FEED
TO T R A N S M I S S I O N t-
CONTROL S Y S T E M >
"\F12 18DB/WT %
( S E E SH 2 5 ) ^-AUTOMATIC
TRANSMISSION
ONLY
TO V E H I C L E FEED
S P E E D CONTROL \ F12 18DB/WT *
( S E E SH 3 3 ) FEED
020 20L6-
TO B A C K - U P
LAMP S W I T C H
r6l[TH-F12 18DB/WT ( S E E SH 2 5 )
RIGHT
DATA L I N K FENDER
BLACK
CONNECTOR SHIELD)
(LEFT SIDE
FENDER
SHIELD)
D21 D20 K19

20PK 20L6 18GY
EN6INE
6R0UND
( R I 6 H T REAR
OF E N G I N E )
5 125 451 19
SIGNAL DATA LINK COIL DRIVER
GROUND #1
( F R O N T L E F T OF ENGINE COMPARTMENT)

BW - 156 WIRING DIAGRAMS J
TO T R A N S M I S S I O N GND
CONTROL MODULE •K4 18BK/LB*-
( S E E SH 2 6 ) K4 18BK/L8*
AUTOMATIC TRANSMISSION 20DG/RD*
Kl
TO CAMSHAFT
GND K6 2 0 V T / W T *
POSITION
-K4 18BK/LB* •
SENSOR BLACK
( S E E SH 20)
MAP SENSOR
TO V E H I C L E .VSS ( R E A R CENTER
S P E E D SENSOR K4 18BK/LB*- \ OF ENGINE
( S E E SH 2 0 ) \ COMPARTMENT)
THROTTLE
POSITION (SENSOR)
(ON T H R O T T L E BODY)
ENGINE INTAKE
COOLANT T E M P E R A T U R E AIR TEMPERATURE
SENSOR (ON SENSOR (NEAR
T H E R M O S T A T HOUSING) T H R O T T L E BODY)
Y
K22
K4
180R K4 K4
K 4
18BK K21
0 B
* 18BK LB* 18BK 18BK 18BK
LB* RD* LB* L B *
Kl K6
20DG 20VT
(NEAR
£35 RD* WT*
THROTTLE (BEHIND (NEAR TO
BODY) L E F T HAND BLACK THROTTLE CRANKSHAFT
EN6INE BODY) POSITION
MOUNT) SENSOR
( S E E SH 2 0 )
^pSND
K4
K6 K22 K4 K4 K2 K21 18BK
20VT I80R 18BK 18BK 20TN 18BK LB*
WT* DB* L B * LB* BK* RD* HD/LP
HD/LP
DASH
K22
180R DASH
DB*
TO
TRANSMISSION
CONTROL K4
MANUAL MODULE 18BK
TRANS ( S E E SH 26) LB*
MISSION
K2 K4 K21 GND Kl
HD/LP 20TN 18BK 18BK 20DG K6
DASH BK* LB* RD* TO HEATED OXYGEN RD* 20VT
SENSOR WT*
(SEE SH 21) X. 1
22 21
T T
T.P.(S) 2 4 INTAKE 1 6
INPUT ECT MAP 5 VOLT
SENSOR INPUT GROUND SEAIR TEMP.
NSOR INPUT SENSOR SUPPLY
POWERTRAN
I CONTROL MODULE
(FRONT LEFT OF ENGINE COMPARTMENT)(CONNECTOR SEE SH 105)
J
BLACK
BLACK
K7 180R
TO INSTRUMENT K4 1 8 B K / L B * j*"
(SEE
CLUSTER
SH 51)
(LEFT SIDE G7 18WT/0R* I
KICK PANEL) i
FEED K4
G7 18WT/0R*
1 8 B K / L B *
I - K 7 180R
G7 20WT/0R* G7 2 0 W T / 0 R *
BLACK
BLACK
K7 180R VEHICLE
K4 18BK/LBX (REAR OF
SPEED
K44 18TN/YL*
ENGINE) SENSOR
(MOUNTED ON
BLACK
TRANSMISSION)
K7 180R
K24 18GY/BK*!
K4 1 8 B K / L B *
•K4 1 8 B K / L B *
- K 7 180R
-K7 180R-
K4
18BK
L B *
HD/LP
DASH K 7
K4 180R
18BK TO DAYTIME RUNNING
CRANKSHAFT L B * LAMP MODULE
POSITION (SEE SH 36)
SENSOR
(LEFT SIDE
GND 67 TFEED
REAR OF 20WT 67
ENGINE)
TO OR* 20WT
OR*
<8>
SPLICE
(SEE SH 19)
CAMSHAFT
^ 7 TO
(SEE
CHARGING
SYSTEM
SH 6)
POSITION
SENSOR HD/LP
Fl
(IN DISTRIBUTOR) DASH FEED
K24
K7
K44 67
18GY 18TN 20WT K20
BK* 180R
Y L * OR*
18D6
24 7 44 47 20
DIST PICK-UP
SIGNAL B +
8 VOLT
SUPPLY
CAMSHAFT
SENSOR
VEHICLE VOLT
PICK-UP
SPEED
SENSOR
REG
INPUT

TO T R A N S M I S S I O N
CONTROL S Y S T E M TO DATA L I N K
( S E E SH 2 5 , 2 6 ) CONNECTOR
( S E E SH 2 5 , 3 0 )
TO TRANSMISSION
CONTROL AUTOMATIC GND
MODULE TRANSMISSION
( S E E SH 26)
GND Z12 18BK/TN*•
AUTOMAT
TRANSMISSION
j Z12 18BK/TN *
TO
ENGINE S T A R T E R „ 6 N D
RELAY V— Z 1 2 18BK/TN*
( S E E SH 8 ) TO
DAYTIME
MANUAL RUNNING
TRANSMISSION LAMP
MODULE
( S E E SH 3 6 )
Z12 18BK/TN*
EN6INE
6R0UND
(RIGHT
REAR OF
ENGINE)
TO DATA L I N K
CONNECTOR
(SEE SH 2 5 , 3 0 )
HEATED
OXYGEN
SENSOR
LEFT SIDE
OF ENGINE I N TWISTED
EXHAUST P I P E ) PAIR
TO ENGINE
TO S T A R T E R RELAY
BALLAST ( S E E SH 8)
RESISTOR
BY-PASS AUTOMATIC x ,
RELAY ONLY \I GND
S E E SH 8 5 ) 1
K41 K37 T41 ZI2 Z12 Dl 02
I8BK 20RD I8BR 16BK I6BK 18VT 18WT
D6X DB* YL* TN* TN* BR* BK*
i i
41
L
37
j 30. II
+ +
12 26
i 1
46
HEATED BY-PASS NEUTRAL PWR PWR BUSS BUSS
OXYGEN RELAY SENSE GRND 6RND (+) H
SENSOR
INPUT P O W E R T R A I N CONTROL MODULE
. FEED
N A R y—BLACK
lsi SH 6) A142 1 8 D 6 / 0 R * — ,
^ (RIGHT S I D E
FENDER S H I E L D )
TO D I S T R I B U T O R , F E E D
I G N I T I O N COIL V—— - A 1 4 2 16DG/0R* A142 16DG/0R* -A142 18DG/0R*—i
( S E E SH 18)
IDLE AIR
CONTROL MOTOR
-BLACK
[\JUUUU- •K59 18VT/BK*
-K59 18VT/BK*
-K40 18BR/WT* -K39 186Y/RD*
-K60 18YL/BK*
-K39 186Y/RD*
|OUUUO" -K60 18YL/BK*
-K40 18BR/WT*
TO AUTOMATIC
S H U T DOWN
I INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR ! INJECTOR 6 RELAY
( S E E SH 17) A142
BLACK BLACK BLACK -j BLACK
BLACK -j BLACK -j* 18DG
OR*
FEED
pi
K l l A142 A142 K13 A 1 4 2 K14 A 1 4 2 K15 A 1 4 2 K16 A 1 4 2
K12
18WT 18DG 18DG 18YL 18DG 1 8 L B 18DG 18PK 18DG 18LG 18DG
18TN
D B * OR* OR* WT* OR* B R * OR* B K * OR* B K * OR*
A142
14DG
OR*
J 1 1 1
rfrn r t n, r ^
a r^ .rî,
t^J L7=TJ LtdJ UFTJ L7=TJ HD/LP
fl iliriflllriflllnflllrifl DASH
•A 142 18DG/0R*
A142 18DG/0R*
A142 18DG/0R*
A142 18DG/0R*
Al 42 18DG/0R*
A142 18DG/0R*
K40 K39
18BR 18GY
WT* RD*
HD/LP
Kll K13 K14 K15 K16 DASH Al42 K60 K59
K12
18WT 18YL 18LB 18PK 18LG 18DG 18YL 18VT
18TN
OB* WT* BR* BK* BK* OR* BK* BK*
X X JL JL JL iT •'
T
16
i 15
T14
T
13
T
38
T
58 |
i 40 60 39 59
57
AUTO
I.A.C. MOTOR
INJECTORS SHUT
DOWN
SENSE
(FRONT LEFT OF E N 6 I N E COMPARTMENT)(CONNECTOR S E E S H 1 0 5 )
J938W-3 SYSTEM ( 4 . 0 L ENGINE) X J 22
J
TO
SPLICE
(SEE SH 18)
FEED
FEED TO POWER
X D I S T R I B U T I O N CENTER
> FUSE F4
F12 (SEE SH 4)
18D8
WT* F141
18LG FAN CONTROL
RD* RELAY
( I N POWER
DISTRIBUTION
CENTER)
(SEE SH 3)
-C25 18LG
[s]cn[l] F12 18DB/WT*
1\ F141 18LG/RD*
-C27 20DB/PK*
1
C27 C25 18LG

20DB
PK*
C25 18LG
RADIATOR
FAN
MOTOR
Z l 18BK
C27
200B
PK*
31
COOLING FAN SPLICE
(SEE SH 5 9 , 6 0 )
XJ 23 4.0L HEAVY DUTY COOLING JS38W-3

TO INSTRUMENT
CLUSTER
INDICATOR
TO INSTRUMENT
( S E E SH 51)
CLUSTER
( S E E SH 51)
FEED
G6
20GY FEED*'TO IGNITION
G20 20VT/YL*- SWITCH
(SEE SH 9)
C6
GRAY
G20 1 8 V T / Y L * !
BLACK
y i
(NEAR ENGINE ENGINE
COOLANT COOLANT
GENERATOR) TEMPERATURE TEMPERATURE
SENDING UNIT SWITCH
( L E F T HAND REAR ( L E F T HAND
OF ENGINE) REAR
OF ENGINE)
G6
18GY
ENGINE ENGINE
OIL OIL
PRESSURE PRESSURE
SWITCH SWITCH
(LOWER (LOWER
RIGHT HAND RIGHT HAND
OF OF
ENGINE) ENGINE)
ENGINE O I L P R E S S U R E
J938W-3 AND TEMPERATURE SYSTEM XJ 24
8W - 162 WIRING DIAGRAMS 4
i—L10 18BR/LG*-
TO POWER
DISTRIBUTION
CENTER F U S E F 5
( S E E SH 4)
TWISTED
PAIR
r
D2
18WT
BK*
CONTROL MODULE
CAVITY 46
( S E E SH 21)
i DATA L I N K
! CONNECTOR
D2
18WT
BK* TWISTED
IMPAIR
{GND
TO
ANTI-LOCK
BRAKE MODULE
( S E E SH 3 0 )
XJ 2 5 TRANSMISSION CONTROL SYSTEM J938W-3

4WD
INDICATOR LAMP
-107 18BK/RD * i
107 106
BLACK
r- 20BK-4*'W^4- 20BK-]
77 Zl 18GY
TRANSMISSION Z12 18BK/TN*-
RD* Y L *
CONTROL
MAGNETIC
T R I G G E R WHEEL
REED
SWITCH
505
508 509 18TN •
18WT 18VT BK*
510
BK* WT* 1
— 18DB -
WT*
505
18TN
BLACK BK* TO T E L L T A L E
(RIGHT S I D E CONNECTOR
OF E N G I N E ) ( S E E SH 5 2 )
107
508
.20BK
— — 18WT 1-lElFlGlH^ RD* FEED
BK* . 106 _
20BK
GRAY ( R I G H T S I D E YL*
OF E N G I N E )
107 2 0 B K / R D * 107 20BK/RD*-

•Z12 18BK/TN *
106 20BK/YL*
SPLICE
( S E E SH 3 2 ) - 107 2 0 B K / R D *
NO CONTINUATION TO
INTO I N S T R U M E N T
PANEL HARNESS GND
(FOR ECE ONLY) -\ 6
TO SPLICE
12 SPLICE ( S E E S H 19)
ftmnm
FEED V
SPLICE S P L II CC E
( S E E SH 2 1 ) ( S E E SHSH 17)
GND
Z12 505 508 509 510 K29
T
18BK A14
T17 18YL 18TN 18WT 18VT 18DB 18WT
TN* 18RD
BK* BK* WT* WT* PK*
177
20TN
1
Cll D7 C3 C14 C15 C16 CIO D14 02 D3
TRANS 6ND SPEED TRANS S2 SI BRAKE A.S.D. T.P.(S) SENSOR
SWITCH SENSOR SOL SOL SOL T/C GND
T R A N S M I S S I O N CONTROL MODULE
(LOWER RI6HT S I D E OF I N S T R U M E N T PANEL)(CONNECTOR S E E S H 9 9 )
J938W-3 TRANSMISSION CONTROL SYSTEM XJ 26

18YL 8 2
i
DB* 18YLI
\ L E F T REAR R I G H T REAR /
\ WHEEL WHEEL /
BLACK BLACK \ SENSOR SENSOR /
1 1 2
I i
i
B3 Bl
B4 B2
18LG 18YL 18YL
18LG
8 8 B6 DB*
B9 D
, * B
TWISTED | TWISTED
IBRD IBRD 18WT
DB* DB* I r P A I R n j
i_ —,—j \f P A I R
V
\ L E F T FRONT RIGHT F R O N T /
V n |
\ WHEEL WHEEL /
\ SENSOR SENSOR / BLACK
155 BLACK
i 2
mm
1
f
i
7L JL
88 B6
B9 B7 / \
18RD 18WT
DB*
18RD
DB*
18WT 1 ( )
i B3 B4 Bl B2
i 18LG 18LG 18YL 18YL
DB* DB*
TWISTED TWISTED
PAIR PAIR
•TWISTED •TWISTED
PAIR PAIR
B8 B6 B3 Bl
B9 B7 B4 B2
I8RD 18WT I8LG 18YL
18RD 18WT 18LG 18YL
DB* DB* DB* i DB*
i i I
i
I I I
A
I
i
I I
i I
30 48 29 47 28 46
f 145 27
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(+) H (+) H (+) H (+)
A N T I - L O C K BRAKE S Y S T E M MODULE
( R I G H T OF S T E E R I N G COLUMN)
XJ 27 ANTI-LOCK BRAKING SYSTEM J938W-3

19
TO ABS
RELAY #2 SPLICE
-Z12 12BK/TN* (SEE SH 29) (SEE SH 29)
TFEED GND BLACK
-8219 18DB 517 18PK/0R*
• BLACK 515 18YL/VT*
•B220 18TN 516 18TN/WT* I
•233 J J T N / J K *
ABS PUMP
MOTOR
B210 18RD/BKX
-TWISTED
BLACK PAIR
B258 186Y/LBX
\ PEDAL
\ TRAVEL
\ N SENSOR (ATTACHED
TO HYDRAULIC
UNIT)
(f-y£
8210 B258
B219 B220 517 515 516
18RD 186Y 18DB 18TN 18PK 18YL 18TN
BK* LB* OR* VT* WT*
41 16 31 49 ,26 25
43
I TRANSDUCER TRANSDUCER BOOST BOOST ACCEL
RETURN FEED PRESSURE PRESSURE SENSOR
RETURN
ANTI-LOCK BRAKE SYSTEM MODULE
(RIGHT OF STEERING COLUMN)
(CONNECTOR SEE SH 103)
U938W-3 ANTI-LOCK BRAKING SYSTEM XJ 28

A20 14RD/DG*
AlO 12RD/DG*
34 Z12 12BK/TN*
rm 235 14GY/YL*
35 33 31 F12 18DB/WT*
60 JM|—233 12TN/BK* 32 235 14GY/YL*
[TT1 — B l 16 18GY 235 14GY/YL*

712 14BK/TN*
-207 18PK
i _ i
TO POWER TO POWER
DISTRIBUTION DISTRIBUTION
CENTER FUSE F 9 CENTER FUSE F7
(SEE SH 4) (SEE SH 4)
FEED
A20
H R D
DGX TO A/C
COMPRESSOR
CLUTCH
Z12 12BK/TN-*-
6 RELAY
/ FEED ( S E ESH 65)
F12
18DB
WT*
33 34 31
ABS ABS
RELAY # 2 RELAY # 1
(IN POWER (IN POWER
DISTRIBUTION DISTRIBUTION
CENTER) CENTER)
32 35
•235 146Y/YLX-
TO A B S 235 207
PUMP MOTOR 14GY 18PK
(SEE SH 28) Y L *
FEED
TO TO
6ND / \ — |
y Z 1 2 1 4 B K / T N * — £ N ^ £ J J (235)
/ SPLICE SPLICE
(SEE SH 2 1 ) (SEE SH 3 1 )
1 [ GROUND
/ \ ( L E F T SIDE
Bl 16 207
186Y 18PK
/ Q \ SHIELD)
15 34
PUMP RELAY ABS
COIL B - RELAY #1

(RI6HT OF S T E E R I N 6 COLUMN)
(CONNECTOR S E E S H 103)
XJ 29 ANTI-LOCK BRAKING SYSTEM J938M-3

WIRING DIAGRAMS SW - 167
TO REAR
LIGHTING SYSTEM
TO FEED (SEE SH 88,90)
-A38 120R/VT*- FEED
SPLICE
(SEE SH 10)
FUSE #7
(2 AMP)
C3 C2
TO TELLTALE
I I CONNECTOR
I
D2
(SEE SH 52)
Dl
18VT 18WT
BK*
BR* TWISTED -*^6ND
PAIR
FEEDJ^ - TO POWERTRAN I
TO POWERTRAN I CONTROL MODULE
CONTROL MODULE CAVITY 46
CAVITY 26 (SEE SH 21)
(SEE SH 21)
(LEFT
(RI6HT OF SIDE
STEERIN6 COWL)
COLUMN)
236 L50
18L6 18WT
TO ABS YL* TN*
DIODE
(SEE SH 31)
23 42 52 53 32
BUSS BUSS YELLOW IGN STOP LAMP
B+ B- LIGHT SWITCH
(RI6HT OF STEERIN6 COLUMN)
J938W-3 ANT I-LOCK BRAKING SYSTEM XJ 30
TO
<^>
- BLACK SPLICE
( S E E SH 3 0 )
m - 2 0 5 18VT
- 2 3 5 14GY
FEED -B245 16WT/LG*
205 -B249 1 6 W T / T N *
18VT -B251 16WT/BK*
-235 14GY/YL*
ABS 5
— BLACK
DIODE Qo
ooO
10
(TAPED IN
HARNESS -B254 160G/0R *
NEAR A N T I -
LOCK MODULE) -B248 16DG/WTX
-B243 16DG/BK*
-235 14GY/YL*
235
ELECTRONIC 14GY
GROUND — 1
YL*
(LEFT ABS HYDRAULIC
SIDE ACTUATION U N I T
COWL) 10
9 8 7 4 3 2
Zl
14BK
HD/LP
DASH
235 B248 B245 8251
Zl 16DG 16WT 16WT
TO ABS 14GY
14BK B243 B254 LG* B249 BK*
RELAY# 1 235 YL* WT*
14GY 16DG 16DG 16WT
( S E E SH 2 9 )
YL* BK* OR* TN*
1 19 33 2 21 36 20 38 54
GROUND GROUND LF RF RR/LR LF RF LR
SOLENOID FEED
DELAY DELAY DELAY ISOLATE ISOLATE ISOLATE
ANT I - L O C K BRAKE S Y S T E M MODULE

( R I G H T OF S T E E R I N G COLUMN)
XJ 31 ANTI-LOCK BRAKING SYSTEM J938W-3

J WIRING DIAGRAMS 8W - 16S
TO HEADLAMP
DELAY MODULE
( S E E SH 4 1 )
(IN
HORN
RELAY
RELAY
CENTER
SEE
SH 107)
RIGHT
SIDE
HORN
•-^W^ jD' I —X2 18DG/RD*
LEFT X2 16DG/RD X •
HORN B R U S H /
SIDE
S L I P RING
HORN
X2 18DG/RDX
BLACK
•A6 1 8 R D / B K *
Z l 18BK
A6 1 8 R D / B K X
UNDERHOOD
LAMP
(ON HOOD) HORN
SWITCH
(ON S T E E R I N G
WHEEL)
GND
„ TO T - C A S E ' 1
r-Zl 1 8 B K 4 LOCK-UP SWITCH —
1
( S E E SH 2 6 )
7 I \pRi/ f TO V E H I C L E S P E E D
Z 1 1 8 B K
7^T3 CONTROL SERVO
6 N D
( S E E SH 3 4 )
GND
Z l 12BK X TO BLOWER MOTOR
> ( S E E SH 6 4 . 6 6 )
Zl 12BK
TO POWER BODY GROUND 2
X DISTRIBUTION =" (RIGHT SIDE
> CENTER F U S E F l SHIELD)
( S E E SH 4 )
J938W-3 UNDERHOOD LAMP/HORN SYSTEM XJ 32

TO POWER
DISTRIBUTION
CENTER
FUSE F13
(SEE SH 4)
TO
SPLICE
(SEE SH 16,18)
L9 16PK/BK* TFEED
-V32 20YL/RD *
HAZARD F12 18DB/WT *
FLASHER
(IN FUSE
PANEL) TO
STOP LAMP '-rfffz,i BLACK
SWITCH
(SEE SH 44) F12
18DB -V31 20BR/RD*
J FEED j FEED J FEED WT*
-V33 20WT/L6*
V32 V30 L9
20YL 20DB 16PK
RD* RD* BK*
SPEED
SWITCH
V32 20YL/RD* - OFF VEHICLE
SPEED CONTROL
BLACK •JOM .
•ON• ° SWITCH
(ON TURN
SET P SI6NAL LEVER)
SWITCH /
B
D xU C
V32 T
6 112 20YL V31 V33
RD* 20BR 20WT
TV32 RD* L6*
2 0 Y L
BLACK J R D
(UNDER INSTRUMENT PANEL . *
LEFT SIDE)
-V30 20DB/RD* V30 20DB/RD*
49 48 50
IGNITION COAST/ RESUME/
SET ACCEL
POWERTRAN I CONTROL MODULE
(FRONT LEFT OF ENGINE COMPARTMENT)
XJ 33 VEHICLE SPEED CONTROL SYSTEM j938u- 3

TO
<§23
SPLICE
( S E E S H 32)
GND
VEHICLE
Zl 18BK (f S P E E D CONTROL
SERVO
(FRONT R I G H T
rV30 20DB/RD* OF ENGINE
COMPARTMENT)
V35 V36
20LG 20TN
RD* RD*
V30 20DB/RD*
53 33
VENT VACUUM

U938W-3 VEHICLE SPEED CONTROL SYSTEM XJ 34

3 CONDUCTOR BLACK
TYPE HPN #18 WITH
GREEN GROUND - C . S . A . APPROVED
ENGINE WALL PLUG

BLOCK COOLANT
HEATER
FEED TO
€ IGNITION
F85 18VT/WT*— 1
A48 12VT- % SWITCH
(SEE SH 9)
FUSE # 2
(15 AMP)
BLACK
CIGAR
LIGHTER
mm
TO LCD
ILLUMINATION
RELAY
(SEE SH 50)
TO RADIO
(SEE SH 67)
GROUND
SPLICE
( S E E SH 58)
ENGINE BLOCK
XJ 35 COOLANT HEATER/CIGAR L I G H T E R J938W-3
W I R I N G DIAGRAMS 8 W - 173
TO POWER FEED
DISTRIBUTION
$- A3 12RD/WT*
CENTER FUSE F 1 2
(SEE S H 4)
FEED
TO <A2p> SPLICE
( S E E S H 12.17)
5 A21 12DB-
VSS
T0<^7>SPLICE
$ - G7 2 0 W T / 0 R *
(SEE S H 11,20)
GND
TO <n2>l| SPLICE
$- Z 1 2 18BK/TN *
(SEE SH 13,21)
Fl
TO INSTRUMENT FEED |£J

S L 3
(HIGH BEAS INDICATOR) ^ 1 6 R D / Y L * - ^ - 4 6 5 1 6 L B / B K * -
(SEE SH5 1 )
FEED
TO F R O N T E N D €
LIGHTING SYSTEM X L 4 16VT/WT*-

(SEE SH 37)
BLACK
Z12 18BK/TN *
L4 16VT/WTX
A21 1 2 D B
465 16LB/BK*
L3 16RD/0R*
A3 12RD/WTX
67 20WT/0RX
TO FRONT END
LIGHTING SYSTEM
(SEE SH 37)
FEED
L3 L4 465 Z 1 2 67 A3
A21
16RD 16VT 1 6 L B 18BK 20WT 12RD
12DB
OR* WT* B K * T N * O R * WT*
\
\
\
\
1 10 4 8 7 5 6
DAYTIME RUNNIN6 LAMP MODULE

(ON RI6HT SIDE SHIELD REAR OF E N 6 I N E COMPARTMENT)
J938W-3 DAYTIME RUNNING LAMP SYSTEM XJ 36

Fl
FEED TO INSTRUMENT
L3 16RD/YL % • £ CLUSTER
( H I G H BEAM I N D I C A T O R )
W/0 D R L - ( S E E SH 5 1 )
W/DRL
FEED TO POWER
465
L3 16RD/0R* 16LB F39 18PK/LG* $ ^^CENTER*^
BK*
FUSE F5
( S E E SH 4)
TO DAYTIME FEED
RUNNING LAMP C
>
MODULE
( S E E SH 3 6 )
F E E D
. TO I N S T R U M E N T
L60 18TN $ CLUSTER
( S E E SH 5 1 )
• F39 18PK/LG * -
F E E D
„ TO T U R N / H A Z A R D
•L60 18TN L60 18TN < SWITCH ASSEMBLY
Gl ( S E E SH 4 3 )
•L35 16BR/WT*
i7K
L35 1CDD/UT*
16BR/WT* } TO FOG LAMP SWITCH
( s £ E $ H 4 Q )
GND
TO < Z j > 4 ] SPLICE
-Zl 16BK Zl 16BK \
-L90 18DB/RD* • (SEE SH 5 9 , 6 0 )
-L60 18TN
-L60 18TN
-Zl 16BK
-Zl 18BK- •Zl 18BK

RIGHT
•L4 16VT/WT*- L4 16VT/WT* HEADLAMP
L3 16RD/0RX - L3 16RD/0R*
—L60 18TN R I G H T PARK

AND T U R N
L90 18DB/RD * SIGNAL
•L90 18DB/RD X LAMP
— Z l 18BK
-Zl 18BK 1
RIGHT S I D E
L90 18DB/RD * - L90 18DB/RD * MARKER
LAMP
FRONT L90>1|
END
- L 6 0 18TN —
Zl>10l FRONT
-Zl 16BK- Zl 16BK

R I G H T FOG
•Zl 18BK- LAMP
(OPTIONAL)
117 14LG/BK % • 117 14LG/BK*-
BLACK
17 14LG/BK:
Zl 16BK
, i
J938H-3 FRONT END LIGHTING XJ 38

TO POWER TO
DISTRIBUTION A3 12RD/WT* IGNITION KEY F34 12TN/BK*
CENTER WARNNIG M2 20YL
FUSE F12 SWITCH E2 200R/BK*-
(SEE SH 4) (SEE SH 70) •L7 18BK/YL*
FUSE #15 L90 18DB/RD*- L7 188K/0R*
(15 AMP) FEED' TO
T
CHM
Q
IE CHMIE A3 12RD/WT* - f e ^ B f l G26 20LB

MODULE MODULE
(SEE SH 70) ;SEE BLACK —^y? Mil 20PK/LB*
TEEED SH 70) — - M l 1 20PK/LB*
L7 feed
18BK
YL* MT
20PK
LB*
FEE
L90 / TO LCD
18DB—ÎLLUMINATION
RD* RELAY
(SEE SH 50)
Bl
L90 FEED TO FRONT
L-isDB ( END LIGHTING
>
RD* , SYSTEM
(SEE SH 37)
TO REAR
LIGHTING SYSTEM
(SEE SH 88,90)
TO FRONT
END LIGHTING
SYSTEM
(SEE SH 37)
^PFEED
L3
HRD
OR*
I
L4 16VT/WT* •
TO FRONT END
LIGHTING SYSTEM
(SEE SH 37)
XJ 33 HEADLAMP SWITCH J938W-3
TO POWER
MIRROR S Y S T E M
TO ( S E E SH 69)
H E A T E D REAR
WINDOW
SWITCH
( S E E SH 6 2 )
G N I
> TO DOOR JAMB
Zl 2 0 B K — \ SWITCH SYSTEM
( S E E SH 7 2 )
G N D
. TO A/C
6ND. TO FOG LAMP Zl 16BK \ THERMOSTAT
L35 16BR/WT*—X RELAY ( S E E SH 6 5 )
' ( S E E SH 3 7 . 3 8 )
SPLICE
( S E E SH 58)
J938W-3 HEADLAMP SWITCH XJ 40

TO POWER
DISTRIBUTION
CENTER F U S E F 1 4 F87 20WT/0R*!
( S E E SH 4 )
TO POWER DOOR , F E E D
F87 20WT/BK*j
LOCKS S Y S T E M V — —
( S E E SH 7 9 )
F34 12TN/BK*j
Zl 18BK
Zl 18BK
TO HORN
RELAY I
( S E E SH 32) X4 166Y/PK*
X4 16GY/0R*
GND
BLACK
v—. . — — _ —
X4
16GY
FUSE # 1 1
PK*
25 AMP)
F E E D
TO T E L L T A L E
F87 20WT/OR* —$ CONNECTOR
>
( S E E SH 52)
FEED X Q p u j up
•F87 20WT/BK* — \ MODULE
( S E E SH 70)
HEADLAMP
BATTERY IGN OFF DELAY MODULE
LIGHTS SIGNAL ( N E X T TO
ON
HEADLAMP
SIGNAL GND
SWITCH)
F34
12TN
Zl
18BK
Zl 18BK
GND
—i
( f TO W I P E R
59,60)
BK*
TO
FEED GND
•Zl 18BK
TO
SPLICE
( S E E SH 40)
SPLICE
( S E E SH 39)
X J 41 HEADLAMP DELAY MODULE J938W-3

Zl 12BK
6ND TO LIFT6ATE
Zl 20BK- ——( SWITCH
>
( S E E SH 7 2 )
GND
6ND„ TO REAR
TO REAR Zl 1 8 B K - — ( W I P E R MOTOR
LIGHTING SYSTEM ( S E E SH 6 1 )
GND LIFTGATE
( S E E SH 8 7 , 8 9 )
TO HEATED
REAR WINDOW
( S E E SH 6 2 )
(LEFT SIDE
OF L I F T 6 A T E )
•Zl 12BK-
Zl 12BK
~ (LEFT SIDE
6R0UND COWL)
r u n TO F U E L TANK
G N P
f L E V E L GAU6E
Zl 14BK- > SENDIN6 U N I T
TO T R A I L E R GND ( S E E SH 8 6 )
TOW STOP C
LAMP R E L A Y > 6ND, TO
Zl 20BK- — — ( S E A T B E L T SWITCH
( S E E SH 9 1 )
( S E E SH 70
TO REAR
LIGHTING SYSTEM
( S E E SH 8 7 . 8 9 )
ToGND
Zl
18BK
GND. TO T R A I L E R
r—( TOW S Y S T E M
>
j ( S E E SH 9 1 )
Zl
TO POWER GND 14BK
SEAT %
( S E E SH 7 4 )
GND TO CONSOLE
I L L U M I N A T I O N LAMP
( S E E SH 4 6 )
6ND
TO REAR
LIGHTING SYSTEM
TO L E F T REAR ( S E E SH 8 8 . 9 0 )
DOOR JAMB S W I T C H
( S E E SH 7 1 )
J938W-3 BODY GROUND XJ 42

TO IGNITION
SWITCH
( S E E SH 9 )
r r F n TO W I N D S H I E L D
W I P E R
Q ——1 CIRCUIT
A48
A 4
1 2 V T (
12VT
BREAKER
(SEE SH 5 9 , 6 0 )
FUSE # 8
( 2 0 AMP)
FEED TO HEATED
F83 18YL/RD*—? REAR WINDOW
C
( S E E SH 6 2 )
F83 18YL/BK* •L5 18BK-
TURN S I 6 N A L
FLASHER
! I N F U S E BLOCK)
Al
TO FEED
FRONT END
L61 18L6 L61 18L6
LIGHTING 5—L61 18L6 —<4^—
SYSTEM
( S E E SH 3 7 )
L60 18TN
L60
18TN
F2
L61 L60 TO REAR
18L6 18TN LIGHTING SYSTEM
L60
E E D (SEE SH 8 8 , 9 0 )
FEEDj^ J/ 18TN
n
F E E D
TO I N S T R U M E N T 1 FEED FEED
CLUSTER
TO FRONT END
( S E E SH 5 1 ) 1
—L61 18L6/BK*
LIGHTING SYSTEM
( S E E SH 3 8 ) L60 18TN/D6*
V32 20YL/RD*
K29 18WT/PK*
K29 18WT/PK*
49 29
IGNITION BRAKE SWITCH MANUAL
INPUT TRANSMISSION
POWERTRAIN CONTROL MODULE (CONNECTOR
(FRONT L E F T OF ENGINE COMPARTMENT) S E E S H 1 0 5 )
XJ 43 S T O P / T U R N AND HAZARD SYSTEM j938w-3

J WIRING DIAGRAMS SW - 181
BLACK
K29 18WT/PK*
Z l 18BK
L9 1 6 P K / B K * STOP LAMP SWITCH
TO POWER
V30 2 0 D B / R D * (ON BRAKE SUPPORT
DISTRIBUTION
V32 2 0 Y L / R D * BRACKET)
CENTER
FUSE F I 3 L50 1 8 W T / T N * GND
(SEE SH 4) TO CHIME
' MODULE S-zi 18BKA<
(SEE SH 70)
TFFEED _ L9 1 6 P K / B K * — - < f
L9
16PK HAZARD FLASHER
K29
BK* (IN FUSE BLOCK) -»- 18WT
A4 PK*
rll- V30
20DB
V32
20YL L50
L9
RD* RD* 18WT
L9 16PK
TN*
16PK BK*
BK*
•L5 18BK*
L12
18VT
TN*
L50
18WT
STRG" STRG TN*
COLUMN COLUMNl
J-ÊD
TO REAR
(FOR CONNECTOR LIGHTING SYSTEM
SEE SH 106) (SEE SH 8 8 , 9 0 )
STRG
COLUMNl
HAZARD (UPPER
L61 18L6-<f SWITCH INSTRUMENT JGL.SL
U NORMAL^ PANEL 7
STRG LEFT
t
COLUMN HAZARD SIDE)
L60 18TN~<f
TURN f-^+Lf \ Z ? L _ \ TURN

AND 1
HAZARD • • • BRIGHT
FLASHER
SWITCH TURN L E F T
STRG
COLUMNl
•L61 18L6/BK*- STRG
1C0LUMN
-L60 18TN/D6*-
•V32 2 0 Y L / R D * -
•K29 18WT/PK*- K29 18WT/PK* -
TO VEHICLE
MANUAL SPEED CONTROL
-K29 18WT/PK*—»
TRANSMISSION SERVO
SEE SH
—K29 18WT/PK* K29 18WT/PK * • FEED 33)
TO
TRANSMISSION f
CONTROL MODULE) K29 1 8 W T / P K * AUTOMATIC TO VEHICLE SPEED

(SEE SH 26) FEED K29>TRANSMISSI0N CONTROL SWITCH
\ / ONLY (SEE SH 33)
HD/LP DASH
J938W-3 STOP/TURN AND HAZARD SYSTEM XJ 44
BLACK
E2 2 0 0 R / B K * i
Z l 16BK
TO RADIO
( S E E SH 6 7 )
FEED
H E A T E R A/C
PANEL LAMP
TO LCD
ILLUMINATION
RELAY
( S E E SH 50)
TO FEED
HEADLAMP
SWITCH
( S E E SH 3 9 ) E2
200R
FEED BK*
TO<Z^3] SPLICE E2
(SEE SH 5 8 )
200R PUSE # j 9
B K
. * ( 5 AMP)
E2 200R/BK*-
E2 2 0 0 R / B K * -
E2 200R/BK -E2 200R/BK*
-E2 200R/BK* E2 200R/BK*-
E2 200R/BK* E2 200R/BK*-
BLACK
E2 2 0 O R / B K X i
Z l 20BK INST/
PNL
E2
200R
BK*
HEATED REAR
REAR
WINDOW
SWITCH
LAMP
WIPER
WASH
SWITCH
LAMP
(JVis LAMP
I NAT I ON
lX ^ — N O T ON
B A S E
20BK XJ
J^6ND
T O < n ^ 2 l SPLICE
(SEE SH 40)
TO H E A T E D
-Zi 20BK-
REAR WINDOW
SWITCH
( S E E SH 6 2 )
XJ 45 INSTRUMENT PANEL ILLUMINATION J938W-3

J
TO I N S T R U M E N T
CLUSTER
( S E E SH 5 1 ) y^—GRAY
FEED
16 16 o 8
a
£ Da (LOWER L E F T S I D E
a
o OF INSTRUMENT PANEL)
a
E2 o
200R
BK*
E2
200R
BK*
-E2 200R/BKX-
E2 200R/BK*-
-E2 200R/BK*
•E2 200R/BKX
J
r-E2 200R/BK*
TO
6ND
- Z l 20BK-5 Vjjll
SPLICE
( S E E SH 4 2 )
BLACK
•Zl 20BK
TRANSMISSION
RAN6E S W I T C H LAMP
(AUTOMATIC T R A N S M I S S I O N ONLY)
J938W-3 INSTRUMENT PANEL ILLUMINATION XJ 46

A6FEED
l 1
p|| ^ I I B^K *! ^ DISTRIBUTION
A6 CENTER F U S E F l
( S E E S H 4)
FUSE # 9
( 1 0 AMP) GLOVE BOX
LAMP . TO
A GND.
21 18BK-
SPLICE
( S E E SH 5 8 )
Ml 20PK
FEED
FEED, TO T E L L T A L E
TO DOME < Ml
Ml 20PK—4 CONNECTOR
LAMP > 20PK
( S E E SH 52)
( S E E SH 49)
M f 1 o r w EEED TO RADIO
Ml 18PK ( S E E SH 6 7 )
M2 20YL
BLACK
20PK
M2 20YL
GND
TO DOME TO R I G H T TO R I G H T
LAMP REAR FRONT DOOR
( S E E SH 49) DOOR JAMB S W I T C H
JAMB ( S E E SH 72)
SWITCH
( S E E SH 72)
XJ 47 DOME AND COURTESY LAMPS J938W-3

F E E D
„ TO L I F T G A T E
G71 2 0 V T / Y L X • ( SWITCH
671 18VT/YL* ( S E E SH 7 1 , 7 2 )
16
GRAY (LOWER L E F T S I D E
OF I N S T R U M E N T P A N E L ) -GRAY
671
, Ml Ml 18VT
' 20PK 20PK YL*
Ml 1 8 P K -
M2 2 0 Y L -
TO POWER DOOR
LOCKS S Y S T E M
( S E E SH 8 1 )
TO L E F T
REAR DOOR
JAMB S W I T C H
M2 M2 ( S E E SH 71)
20YL 20YL
TO L E F T -G71 20VT/YL*—,
FRONT DOOR
JAMB M2 1 8 Y L
; 20PK Ml
SWITCH
(SEE SH 71) O D D D-EH" 20PK
GNDT
M2
20YL CAR60
M2 2 0 Y L
LAMP
671 20VT/YL * \
, 6ND
TO HEADLAMP
SWITCH
( S E E SH 3 9 )
J938W-3 DOME AND COURTESY LAMPS XJ 48

TO
SPLICE
( S E E SH 47)
F E E DTO K E Y L E S S
ENTRY
—C MODULE
^ ( S E E SH 79)
TO K E Y L E S S „
E N T R Y MODULE i
( S E E SH 79) ^ N D
TO POWER C
DOOR LOCKS *
6 N D
SYSTEM
( S E E SH 7 9 )
XJ 49 DOME AND COURTESY LAMPS J938W-3

TO FRONT END L I G H T I N G
( S E E SH 3 7 . 3 8 )
FEED
L90
18D6
RD* Bl
TO REAR
END L I G H T I N G S Y S T E M f FEED
( S E E SH 8 8 . 9 0 ) ) •L90 18DB/RD* •
TO RADIO
( S E E SH 6 7 )
L90 18DB/RD * •
F E E D | TO < E 2 > S P L I C E
E2 200R/BK*-
(SEE SH 45)
L.C.D.
ILLUMINATION
RELAY
IN RELAY CENTER
S E E SH 1 0 7 )
E2 200R/BKX
X5 18LB/RD*
L90 18DB/RD*
TO •F85 18VT/WT*
WINDSHIELD
WIPER SWITCH
Zl 188K
( S E E SH 5 9 . 6 0 )
, , , — J
(SEE SH 3 5 . 6 7 )
J938W-3 L.C.D. ILLUMINATION RELAY XJ 50

TO
TO TO FUEL INJECTION TO ENGINE COOLANT
SYSTEM TEMPERATURE
(SEE SH 11,20) SWITCH
SPLICE (SEE SH 24)
(SEE SH 10) SPLICE
TO ENGINE OIL (SEE SH 45,46 FEED
FEEO T FEED
PRESSURE AI G20
AND TEMPERATURE FEEDT 20VT
SYSTEM 12
D B YL*
E2
(SEE SH 24) TO CHM IE X 200R 67
MODULE BK*
FEEDT (SEE SH 70) 20WT jo
G6 OR* DAYTIME
20GY RUNNIN6 G20
LAMP 20VT
MODULE YL* G 20
20VT
C6| (SEE SH YL*
36)
FEED J-% FEED
G6 TO
206Y G7 IGNITION
20WT
OR*
465 SWITCH
16LB
BK*
(SEE SH 9)
•612 20DG/BK*
BLACK
K54 20LG/0R*-
TO FRONT END . an
•OD , , FEED TO FRONT END
(SEE SH 38) FEED
OD- G21 20GY/LB* ,kpn—C LIGHTING
•
•
•
L>
D-
D-
L3 16RD/YL*- Hll > SYSTEM
0R
TO
T2 l
'* - « " 200e - 0 0 -
•G20 20VT/YL*-
Fl * (SEE SH 38)
SYSTEM FEED
Bl Al INSTRUMENT
(SEE SH 85) CLUSTER
TO FRONT END CONNECTOR
LIGHTING C , . (SEE SH 102) Z l 20BK
SYSTEM > ~ J ; K6 11 1FTIR
1 8 L G
(SEE SH 37) F D E E
•629 20BK/TN*- G29 20BK/TN * •

G29 G12 K54
20BK 20DG 20LG
TN* YL* OR* 63 20BK/PK*
H6 MALFUNCTOIN
INDICATOR
A7 r- LAMP
629 IB4
20BK A2'
TN* 6ENERAT0R UPSHIFT-
INDICATOR 621 LAMP K54 63
LAMP 20GY MANUAL 200R 20BK 624
LB* TRANS BK* PK* 20GY
MISSION
WASHER TAC HOMETER ONLY .. r PK*
FLUID
LEVEL
SIGNAL i 1 L
SWITCH 43 36 54 32 56
(IN WASHER/ POWERTRAN I CONTROL MODULE
F12 FLUID (FRONT LEFT OF ENGINE COMPARTMENT)
18DB/WT* RESEVOIR) (CONNECTOR SEE SH 105)
BLACK
G29 FEED
20BK/TN* 1
F12 18DB/WT* — J TO <F12> SPLICE
(SEE SH 16,18)
X J 51 INSTRUMENT CLUSTER J938W-3
TO T R A N S M I S S I O N TO
CONTROL S Y S T E M
( S E E SH 2 6 )
SPLICE
1
FEED FEED I
( S E E SH 4 7 )
107
106
20BK T FEED
20BK
RD* YL*
B5 Ml
-107 20BK/LB*• CI 20PK
•106 20BK/YL*
Ml 20PK
F87
-20WT-
BK* K54
20L6
OR*
„ TO PARK
II nE 203 18D6-
FEED
( BRAKE
, SWITCH %
FEED TO ANTI-LOCK
( S E E S H 63
205 18YL } BRAKE
SYSTEM
F87 20WT/BK * ( S E E SH 3 0 )
TELLTALE
CONNECTOR
( S E E S H 101)
FEED
r TO HEADLAMP
•F87 20WT/OR*- "5 DELAY MODULE
( S E E SH 41)
6ND
i T0<Z^2]SPLICE
( S E E SH 4 0 ) FEED , TO CHIME
\ MODULE
( S E E SH 70)
BLACK
(LEFT SIDE
COWL)
J938W-3 INSTRUMENT C L U S T E R INDICATORS XJ 52

ABS RED
INDICATOR LAMP
W' ( S E L E C T TRAC)
INDICATOR LAMP
, F ^ L TIME
INDICATOR LAMP
MAINTAINANCE R E Q U I R E D
INDICATOR LAMP
SEAT B E L T
WARNING
INDICATOR LAMP
MALFUNCTION
INDICATOR
LAMP
, LOW WASHER
I N D I C A T O R LAMP
ABS
GREEN UPSHIFT
INDICATOR INDICATOR LAMP
LAMP
INSTRUMENT CLUSTER
INDICATOR PRINTED
CIRCUIT BOARD
(WITH ABS)
XJ 53 J938W-3
PARK BRAKE
INDICATOR LAMP
4WD
( S E L E C T TRAC)
INDICATOR
LAMP
FULL TIME
INDICATOR LAMP
MAINTAINANCE
REQUIRED
INDICATOR
LAMP
SEAT B E L T
WARNING
INDICATOR LAMP
MALFUNCTION
INDICATOR
LAMP
LOW WASHER
INDICATOR LAMP
BLANK UPSHIFT
INDICATOR LAMP
INSTRUMENT CLUSTER
INDICATOR PRINTED
CIRCUIT BOARD
(WITHOUT ABS)
J938W-3 X J 54
FUEL GAUGE
COOLANT ATTACHING
TEMPERATURE SCREWS
GAUGE
ATTACHING
SCREWS
LOW FUEL WARNING

MODULE ATTACHING
SCREWS
TACHOMETER
ATTACHING
SCREWS
SPEEDOMETER
1. ILLUMINATION LAMPS
ATTACHING
2. RIGHT TURN INDICATOR LAMP
SCREWS
3. HI-BEAM INDICATOR LAMP
4. L E F T TURN INDICATOR LAMP
VOLTMETER
ENGINE OIL ATTACHING
PRESSURE SCREWS
GAUGE
ATTACHING
SCREWS
STANDARD INSTRUMENT CLUSTER

PRINTED CIRCUIT BOARD
XJ 55 J938W-3
j WIRING DIAGRAMS 8W - 193
LO-LINE INSTRUMENT CLUSTER

PRINTED CIRCUIT BOARD
J938W-3 XJ 56
8W - 194 WIRING DIAGRAMS 4
H I - L I N E INSTRUMENT C L U S T E R
XJ 57 P R I N T E D C I R C U I T BOARD J938W-3
TO CIGAR GND 6ND TO<Zr^2lSPLICE

LIGHTER GROUND £ Z l 18BK Zl 126K £
TO GLOVE BOX .GND 6ND

LAMP } Z l 18BK Z l 20BK \ TO DOME
(SEE SH 47) (SEE SH LAMP
49)
TO ASH TRAY v G N D
GND JO RADIO
LAMP J Z l 20BK Zl 18BK 1 6R0UND
GND TO
Zl 18BK \ HEADLAMP SWITCH
(SEE SH 39)
Z l 12BK-
GND TO HEATED REAR

Zl 18BK \ WINDOW RELAY
6R0UND (O (SEE SH 62)
(RIGHT S I D E
KICK PANEL)
TO RIGHT DOOR .GND

JAMB SWITCH £ Z l 20BK
(SEE SH 72)
INST/
Zl PNL
16BK
GND TO HEATER A/C
) PANEL LAMP
c
( S E E SH 45)
J938W-3 INSTRUMENT PANEL GROUND X J 58

FUSE #5
(25 AMP) TO H E A T E R I
C N ING
y-C7 1 2 B K / T N * ^ ° ^^J
( S E E SH 6 4 , 6 6 )
WIPER/WASHER SWITCH
(ON T U R N S I G N A L S T A L K )
TO
RADIATOR
FAN MOTOR
GND ( S E E SH 23)
XJ 59 FRONT WIPERS/WASHER (STANDARD) J938W-3

FUSE #5 TO HEATER I AIR CONDITIONING

(25 AMP) SYSTEM (SEE SH 64.66)
. TFEED
GND TO RADAI TOR

FAN MOTOR
(SEE SH 23)
J938W-3 FRONT WIPERS/WASHER (INTERMITTENT) XJ 60

BW - 198 WIRING DIAGRAMS J
A38 120R/WT* TO
FEED
(MB)
A38 120R-
SPLICE
( S E E SH 10)
FUSE # 1
( 2 5 AMP)
•NATURAL
(ON
i V15 18LB/RD*
INSTRUMENT
PANEL TO
LECH ^ ~ V 2 0 18BK/WT* R I G H T OF
V13 18BR/RD* STEERING
COLUMN)
-F20 18WT
i i
GRAY
(LEFT LOWER INST PANEL) RED

REAR W I P E R /
WASHER S W I T C H y* (LEFT REAR
QUARTER PANEL)
V13
188R
RD*
REAR
WASHER
PUMP
(BELOW
WASHER BLACK
BOTTLE) ( L E F T LOWER TOclDy] |pHAy
I N S T PANEL)
B l J [§3]
GND TO FRONT
Zl 1 8 B K — — ( WASHER V13 18BR/RD*-
>
PUMP F 2 0 18WT-
( S E E SH 5 9 , 6 0 ) V20 18BK/WT*-
188K
BLACK
GND
Z l 18BK
V20 1 8 B K / W T *
TO REAR
WIPER V13 1 8 B R / R D *
MOTOR F 2 0 18WT
SPLICE
(SEE SH 5 9 , 6 0 )
TO
6ND.
Zl 18BK-
SPLICE
(SEE SH 42)
XJ 61 REAR WIPER/WASHER J938W-3

-CIS 12BK/WT*
TO POWER
DISTRIBUTION
m
CENTER 8 RED
3T
FUSE FIO
( S E E SH 4) Z l 20BK TO H E A T E D
Z l 20BK REAR WINDOW
^FEED C80 18DB/WT* S W I T C H LAMP
— L ( S E E SH 4 5 )
12BK HEATED REAR WINDOW SWITCH
RD* GND
-C15 12BK/WT *
A4 TO IGNITION TEED
12BK SWITCH V——
RD* ( S E E SH 9)
JL
TO T U R N
SIGNAL F L A S H E R
FUSE #18 ( S E E SH 4 3 )
18 ( 2 5 AMP)
FEED
F83
18YL
B K
* is TO FOG
(20 AMP) LAMP S W I T C H
( S E E SH 40)
( A L L EXCEPT
BASE)
Zl 18BK
JGND
IGNITION OFF GROUND
TO SPLICE
ON SIGNAL
CONTROL
HEATED REAR WINDOW R E L A Y (SEE SH 58)

(IN RELAY CENTER
S E E SH 1 0 7 )
GRID
'-CIS 12BK WT*-i
(LEFT SIDE
KICK PANEL)
1
( L E F T S I D E OF
9, T A I L G A T E AT G R I D )
BLACK
(RIGHT SIDE
OF T A I L G A T E
AT G R I D )
TO SPLICE
(SEE SH 4 2 )
*\
GND
-Zl 12BK UD-Z1 ^BK-^J^ ^ 1
( B E H I N D L E F T REAR
INNER FENDER PANEL)
J938W-3 HEATED REAR WINDOW XJ 62

8 W - 200 W I R I N G DIAGRAMS
FEED TO T E L L T A L E
CONNECTOR
(SEE SH 52)
TO
IGNITION
SWITCH
( S E E SH 9)
F4 r~G9 18GY/0R*
FEED
T
G9
20GY
WT*
F5 -BLACK
( L E F T SIDE
UNDER INSTRUMENT PANEL) • I
G9 20GY/BK*•
D O
BRAKE
WARNING G9 20GY/BK*!
SWITCH
(BELOW
MASTER
CYLINDER)
- BLACK
G9 20GY/WT* j
PARK
BRAKE
SWITCH
(ON PARK
A
BRAKE)
\
XJ 63 PARKING BRAKE SWITCH J938W-3

(SE SH 16,18) F12 18DB/WT*

F12
18DB
WT* A/C
I FEED COMPRESSOR ABS ONLY
CLUTCH RELAY
TO POWER (RELAY IN POWER F12
DISTRIBUTION DISTRIBUTION 18DB
CENTER FUSE F6 CENTER) WT*
(SEE SH 4 ) (SEE SH 3)
14DB/BK* j
18DB/WT* |
18DB/WT* I C90 C13
20DB FEED
16L6 j 1 6 L G
OR* TO ABS RELAY #1
20DB/0R*! BK* (SEE SH 29)
HD/LP BLACK
DASH LEFT SIDE
FENDER
SHIELD)
C90 16L6 C90 16LG/WT*-
C3
14DB
B K
- * A/C LOW
PRESSURE SWITCH
C90 (LEFT SIDE
16L6 OF CONDENSOR)
C91 A
A/C 16LB
THERMOSTAT
C21 16DB/0R*
•Zl 16BK-
(RI6HT SIDE 6ND
, A/C HEATER C91
i H0USIN6) 16LB
TO
-BLACK
-Zl 16BK
-C21 16DB/0R*
65
•BLACK :z7y2]
-C91 16LB fo)lF"C3 14DB/BK* SPLICE
(SEE SH 40)
C90 C91 C13
16L6 16LB 20O DB
R*
1 X
T -C3 14DB/BK*—i
28 27 34
A/C A/C A/C A/C
SELECT REQUEST RELAY COMPRESSOR
POWERTRAN I CONTROL CLUTCH
MODULE) (FRONT OF
(FRONT LEFT OF ENGINE)
EN6INE COMPARTMENT)
XJ 65 HEATER AND A/C SYSTEM J938W-3

W I R I N G DIAGRAMS 8W - 203
FEED jo IGNITION SWITCH
A48 1 2 V T — i ( S E E SH 9 ) r—\m BLACK

INST/
A48 1 2 V T — 4 T O WINDSHIELD WIPER PNL ULh—C43 12YL/BR*
FEED C I R C U I T BREAKER nDTf- C7 T 12BK/TN*
( S E E SH 5 9 , 6 0 ) S3
L
[T>P C7 12BK/TN*
FUSE #5
( 2 5 AMP) C90 16L6/WT*
-C7 12BK/TN * C7 12BK/
128K/TN*—i
C7 12BK/TNX- D
A/C MODE
SELECTOR
SWITCH
( C E N T E R OF
INSTRUMENT
PANEL)
C43 12YL/BR * - C43)

C43 12YL/BR*-
INST/
C43 PNL
12YL
BLOWER
BR*
SWITCH
( C E N T E R OF
BLOWER
INSTRUMENT
RESISTOR
C90 16L6/WT*- PANEL)
(RIGHT S I D E
OF H E A T E R /
A/C HOUSING)
C
C4 12TN- <f
[7}-C4 1 2 T N
[i}-Cl 12DG
JS— BLACK
BLACK
IT— C43 1 2 Y L / B R *
U
C4 1 2 T N
CI 12DG
CI 12DG
- Z l 12BK { TO [ l 2 ^ > S P L I C E
(SEE SH 32)
J938W-3 HEATER AND A / C SYSTEM XJ 66

TO IGNITION
SWITCH
(SEE SH 9)
A48 12VT- FUSE #2
(15 AMP)
X51 18BR/YL*- {JJS-T-X57 18BR/LB* FEED
X53 18D6- {2][l}^~X55 18BR/RDX
TO LCD
|X60 18DG/RD *- {3]M X5 18LB/RD * I
L LUMI NATION FEED
RELAY h
BLACK (SEE SH 5 0 )
Ml 18PK —
F85 18VT/WT*- {HLHI E 2 180R/BK* TO TO LCD
ILLUMINATION
X54 18VT — { 6 J E ^ - X 5 6 18DB/RD * RELAY
SPLI CE (SEE SH 50)
L
X52 18DB/WT *- {TJIOH--X58 18DB/0R* (SEESH 45) 18LB
. ,
V
X5
FEEDT_
. —. i —_ ,— 1
7 ?EED RD* F85 18VT/WT*

ITO ^Ml^rj SPLICE E2
5—Ml 18PK 1 180R
BK* FEED F85 18VT/WT*
(SEE SH 47) TO CGI AR LIGHTER
FEED (SEE SH 35)
4 11 10 5
RADO
I RADOI
ANTENNA 6
R 0
U ND
INPUT 92 13 7 8 1 6 12
17
ANTENNA
MAST T T T T
X52 X51 X54
X53 18DB 18BR 18VTX56 0
18DG X58 WT* X57 GRAY YL*
18DB 18BR (LEFT SIDE 18DB
OR* LB* PK ICK RD* ^ ^
X55 ANEL)
18BR 18BK"
RD*
GRAY—i
X53
18DG LEFT
(LEFT LOWER I/P) FRONT
LEFT GREEN- DOOR r,ll
G3 S3
Hm
"
INSTRUMENT SPEAKER ca
i i
cS
a es
<C3
ea ca t
e
PANEL U
y
SPEAKER
X58
\
20DB
OR*
-X55 20BR/RD*
1
X55 18BR/RD* -X53 20D6
—X55 20BR/RD*
X53 18D6 BLACK
X53 20D6 (LEFT REAR
RADIO PANEL)
XJ 67 ( 4 SPEAKER SYSTEM) J938W-3
GND TO < n > 3 l S P L I C E
(SEE SH 58)
Zl
188K
GREEN
X54 18VT- X54 20VT-I
RIGHT RIGHT
INSTRUMENT FRONT
PANEL DOOR
SPEAKER SPEAKER
X56
i— X56 1 8 D B / R D * 20D6
RD*
Zl
188K
BLACK •X54 20VT
•X56 2 0 D B / R D *
71 Kl 1
X56
—X56
18DB/RD*
20DB/RD*
-BLACK
X54 18VT
X54 20VT
(INSIDE
LIFTGATE)
QDEEE EEEE
ODEEE Emm
— X51 2 0 B R / Y L * •
g BLACK
X52 20DB/WT*
X57 2 0 B R / L B * X58 20DB/OR*
X52 20DB/WT* X51
X58 20DB/0R*- 20BR
YL* X58
20DB
OR*
X57
LEFT 20BR RIGHT
LIFTGATE LB* LIFTGATE
BLACK B
SPEAKER 1
«l SPEAKER
X57 20BR/LB*j
X51 20BR/YL*U"^
RADIO
J938W-3 (4 SPEAKER SYSTEM) XJ 68
8W - 208 WIRING-DIAGRAMS J
GND TO POWER WINDOW

FEED „ TO POWER DOOR •Zl 20BK- (
7
, SYSTEM
——C LOCK SYSTEM (SEE SH 75)
>
(SEE SH 8 0 , 8 1 )
M
F KEYLESS
•Zl 20BK- J ENTRY MODULE
P38 (SEE SH 79)
200R TO
WT* HEADLAMP GND G N D
SWITCH SYSTEM )
f
Z l 14BK F POWERVOR
•Zl 20BK J LOCK RELAY
jCROSS
•Zl 20BK BODY
POWER MIRROR SWITCH ASSEMBLY
(CENTER CONSOLE)
SWITCH 1 SWITCH 2
OFF OFF SWITCH 3 iNOTEi

FOR POWER MIRROR
SWITCH FUNCTIONS
ft? ft. SEE SH 84
SWITCH 4
T \ - R
P80 20YL
I f V f I f w f
— 1
# R § P81 20DB
P77 20WT/BK*
Zl P79 |[E}-P78 20YL/LG*

20BK 20DB
IITQ-P38 2 0 0 R / W T *
TO 0 0 0 R JAMB
SWITCH SYSTEM
( S E E SH 7 1 )
FEED SEAT B E L T
SWITCH G10
(IN SEAT B E L T ) 18LG
626
20LB
TO <k212U S P L I C E Zl
20BK
( S E E SH 10) STRG
COLUMN
FEED
(UNDER
IE
DRIVER
SEAT'
IGNITION
KEY WARNIN6 BLACK
SWITCH
(IN S T E E R I N 6
FUSE #17 COLUMN) TO
(7.5 AMP)
GND
•Zl 20BK-
SPLICE
(SEE SH 42)
Mll
20PK
LB*
TO TO
INSTRUMENT STRG
CLUSTER COLUMN" G10 18LG
( S E E SH 5 1 ) F E E D
GRAY
F87 SPLICE (LEFT SIDE
20WT (SEE SH 40)
TO FEED KICK PANEL)
BK* Mil
HEADLAMP
20PK GND
D E L A Y
/ , LB*
(SEE SH 41)
TO BRAKE
SWITCH
SEE SH 44)
TO TO FEEO^x
HEADLAMP HEADLAMP ^ TO T E L L T A L E
SWITCH SWITCH CONNECTOR
(SEE SH 39) ( S E E SH 39) ^ (SEE SH 52)
F87
'Tn
|FEED 20WT
L7 BK* 7 F 8
FEED
Gil
18BK I 20WT
20WT
YL* \ B K *
1
B2 A4 B3 A2 A3 Al
CHIME MODULE
(ON F U S E P A N E L )
J938W-3 CHIME MODULE XJ 70

18YL-
GND. T0<M2>SPLICE
M2 2 0 Y L \ X /
18YL-
( S E E SH 4 8 )
L E F T FRONT FEED. TO HEADLAMP

DOOR JAMB BLACK- G26 20LB \ SWITCH
SWITCH ( S E E SH 39)
I8BK
_ c c n TO IGNITION
roc
G26
to. R
18LB
lZz£fi K E Y
WARNING
SWITCH
( L E F T SIOE
KICK P A N E L ) ( S E E SH 7 0 )
GND TO <ZlT2i SPLICE

Zl 20BK——( , ^ .
>
( S E E SH 40)
- BLACK
-M2 18YL r N n TO DOME AND
b W U
r COURTESY
-Zl 20BK M2 18YL-
> LAMP S Y S T E M
( S E E SH 4 8 )
I- . . A
L E F T REAR DOOR
JAMB S W I T C H
(LEFT B PILLAR)
GND TO v C l D S P L I C E
Zl 20BK——A . N /
* ( S E E SH 4 2 )
TO
<^0> "ED FEED TO L I C E N S E

L90 2 0 D B / R D * — ( , LAMP
\y I L90 18DB/RD* >
( S E E SH 8 7 . 8 9 )
SPLICE
( S E E SH 8 7 . 8 9 )
TO CARGO x
, LAMP % 7 G71 20VT/YL* 97 20GY'

( S E E SH 4 8 ) £ BLACK
(INSIDE LIFTGATE)
XJ 71 DOOR JAMB SWITCH SYSTEM J938W-3

WIRING DIAGRAMS 8W - 20S
GND
T0<M22U SPLICE
18YL-
5 M2 20YL
(SEE SH 47)
ltf RIGHT FRONT

DOOR JAMB
2^ SWITCH
(RIGHT S I D E
TOCZlTH SPLICE . G N D
KICK PANEL)
V Z l 20BK 18BK
(SEE SH 58)
-BLACK
-M2 20YL
CD -Zl 20BK
T0<M2jT|$PLICE
CD
BLACK •M2 20YL , i
5 M2 20YL
(SEE SH 47)
RIGHT REAR
JD Jcd DOOR JAMB

SWITCH
T O < Z l > ! SPLICE G N D (RIGHT B - P I L L A R )

V^— V -zi 20BK
Zl 20BK-
(SEE SH 40)
BLACK •97 20GY
97 20GY
L I F T G A T E SWITCH
C
m
D
(INSIDE LIFTGATE) BLACK
Zl 20BK- Zl 20BK
TO
GND
21HI J.
SPLICE
(SEE SH 42)
J938W-3 DOOR JAMB SWITCH SYSTEM XJ 72

POWER S E A T MOTOR I N S U L A T O R POLARITY

B +
S E A T MOVEMENT
POLARITY POLARITY
TN WT FORWARD
WT TN REARWARD
YL LG REAR UP
LG YL REAR DOWN
OR LB FRONT UP
LI OR FRONT DOWN
RD — FEED
— BK GROUND
RED
10 HRD All HRD•
Zl HBK -
L E F T POWER
SEAT SWITCH
—4 ^—
FWD BACK
REARIT *^TFRONT Itef 1FRONT
UP #
N / m
UP DWN • N P OWN
TV 'vT
L E F T POWER
S E A T MOTOR
ASSEMBLY
XJ 73 POWER S E A T J938W-3
TRAILER
TOW ONLY
FEED
TO REAR
LIGHTING SYSTEM All HRD
(SEE SH 87) All HRD
IN L I N E CIRCUIT
BREAKER 10 AMP
(TAPED TO HARNESS BEHIND
L E F T REAR PANEL)
TO STOP LAMP All

RELAY HRD" All
(SEE SH 91) HRD
BLACK-
D 0
D Q
D 0
All HRD NO
CONNECTION ::a
Zl HBK - TO FUSE
PANEL
POWER ACCESSORY All HRD
(SEE SH 93)
BLACK
All
HRD
TO
GND,
-Zl HBK- :zi5n
SPLICE
(SEE SH 42)
BLACK
(UNDER
CENTER
WWr cc
CONSOLE)
-All HRD
"Zl 14BK-
J938W-3 POWER SEAT XJ 74

LEFT
FRONT
Q21 14WT
QI1 MLB
RIGHT
FRONT
026 14VT/WT*
016 14BR/WT* •
028 14D6/WT*
027 14RD/BK*-
LEFT
REAR
GND
TO<n^m$PLICE
BLACK ^ E E SH 69)
017 14DB
RIGHT
REAR Ql 14YL-
( L E F T FRONT
DOOR)
iNOTEi
FOR WINDOW S W I T C H
FUNCTIONS S E E SH
83.84
XJ 75 POWER WINDOWS J938W-3

FEED TO L E F T
•Q21 14WT- FRONT DOOR
WINDOW
-011 14LB- MOTOR
FEED
S E E SH 77)
-
F E E D
-016 14BR/WT* Q16 14BR/WT*-£
-Q26 14VT/WT* 026 14VT/WT*^

FEED TO R I G H T
FRONT
(RIGHT S I D E DOOR WINDOW
Q21 14WT- SWITCH
KICK PANEL)
Qll 14LB- ( S E E SH 7 7 )
FEED.
•Ql 14YL Ql 14YL——{
TO F U S E
F81 12TN F81 12TN PANEL TAP
( S E E SH 93)
026 14VT/WT*
Q16 14BR/WT*
Q28 14DG/WT*
027 14RD/BK*- Q27 14RD/BK*—J

FEED
TO L E F T
FEED REAR DOOR
Ql 14YL $ WINDOW
SWITCH
( S E E SH 78)
FEED,
Q17 14DB Q17 14DB/WT*-}
Q18 14GY/BK*- BLACK
Ql 14YL Ql 14YL (LEFT KICK PANEL)
Ql
CROSS
BODY
DOOR ONLY
(RIGHT .
PILLAR)
TO R I G H T
—Ql 14YL- Ql 14YL- REAR DOOR
-Q28 14DG/WT* Q28 14DG/WT*- WINDOW
-Q18 14GY/BK* Q33 14BR/LB*- SWITCH
S E E SH 7 8 )
NATURAL
J938W-3 POWER WINDOWS XJ 76

RED
Qll MLB
021 MMT
FEED LEFT
TO POWER 021 MWT •
WINDOW FRONT
SYSTEM DOOR
( S E E SH 76) -Qll MLB • WINDOW
FEED MOTOR
RI6HT FRONT DOOR

WINDOW SWITCH
„FEED UP
y— Q16 1 4 B R / W T * - -<f -Q12 14BR- RI6HT

FRONT
TO POWER DOOR
WINDOW WINDOW
SYSTEM , MOTOR
(SEE SH 76) „ FEED
-Q22 1 4 V T -
y— 0 2 6 M V T / W T * (f
DOWN
5 Ql 14 Y L <f % •
FEED
I
I
:
Qt6""i4BR7wti
-Q22 M V T
-Q12 MBR
-Q26 1 4 V T / W T * Q22 MVT i
-Ql M Y L
(—ui L *f I L Q12 MBR !
RED !
O O O O
\ Z Y X W V U /
iNOTEi
FOR WINDOW SWITCH
FUNCTIONS S E E SH
83,84
XJ 77 POWER WINDOWS J938W-3

WIRING DIAGRAMS 8W - 2 1 5
L E F T REAR DOOR
WINDOW SWITCH
i—«-
, FEED UP
-Q12 14BR- LEFT
)—Q27 M R D / B K * <f -»-
TO POWER
XT REAR
DOOR
WINDOW
WINDOW ® MOTOR
SYSTEM
(SEE SH 76)
„ FEED
y— Q17 M D B / W T * <f
-Q22 14VTr «- ¥
DOWN
-Q22 14VT
9 FEED -Ql 14YL-
<3>- -Q27 14RD/BK*I 14VT j
II d H { — Q l H Y L 14BR !
(D- -Q12 14BR
i
•Q17 14DB/WT* Ii
RI6HT REAR DOOR

WINDOW SWITCH
i—«-
" FEED
5—Q28 14D6/WT* (f
UP
-»- -Q12 14BR- t RIGHT
TO POWER
XT REAR
DOOR
WINDOW
WINDOW
SYSTEM „GND
® MOTOR
(SEE SH 76) -Q22 14VTr «- Y

y— Q33 1 4 B R / L B * ( f DOWN
5 Ql 14YL- -<f -Q22 14VT
L _ FEED BLUE
(D- -Q33 1 4 B R / L B * j MBR i
I
]f 0>-ff —Ql HYL MVT
0> -Q12 14BR
•Q28 1 4 D 6 / W T * i
L , J
iNOTEi
FOR WINDOW SWITCH
FUNCTIONS S E E SH
83.84
J938W-3 POWER WINDOWS X J 78

J
TO POWER DOOR
LOCK SYSTEM
(SEE SH 81)
FEED FEED
•P3B 20OR/VT*-
•P35 2 0 0 R / V T * -
POWER DOOR UNLOCK

RELAY
(IN RELAY CENTER
SEE SH 107)
Zl
20BK
HEADLAMP H< 1 6 G Y / 0 R * - «
DELAY MODULE
SEE SH 41) • FUSE 1 4 -
POWER (25 AMP)I I A 7

V
DISTRIBUTION ' *7
L
KEYLESS ENTRY MODULE CENTER FEED < ™

Y L
(IN OVERHEAD CONSOLE) FUSE F 1 4 _ A7 . *

1
(SEE SH 4) 5—12RD «
Y L *
El
XJ 79 POWER DOOR LOCKS J938W-3
P35 200R/VT*
- P2 1 8 B K / W T * -
P34 1 8 P K / B K * -
P36 2 0 P K / V T * -
mv
D
RED
D
•BLACK
-P35 200R/VTX
•P36 20PK/VT*
-P35 200R/VT*-
-P2 18BK/WTX
-P34 18PK/BK*
P36 20PK/VT * •
P36 2 0 P K / V T * • (SEE
SH 81)
P35 2 0 0 R / V T X -
BLACK
P38 200R/WT*
-P38 200R/WT*
-P34 18PK/BK*
•P35 200R/VT*
-P35 200R/VT*
P36 2 0 P K / V T *
P36 20PK/VTX
- P2 1 8 B K / W T *
P38 NATURAL
200R
WT* - P 2 18BK/WT*
P34 1 8 P K / B K *
P34 1 8 P K / B K *
FEED
TO POWER
MIRROR SWITCH
(SEE SH 69)
J938W-3 POWER DOOR LOCKS XJ 8 0

J
BLACK
(LEFT
SIDE
COWL) P38 140R/WTX— 1
L E F T DOOR
LOCK SWITCH
P36 14PK/VTX
P35 140R/VT*
(INSIDE P2 14BK/WTX- P2 14BK/WT* -

LEFT P34 14PK/BK*- P34 1 4 P K / B K * -
FRONT
DOOR)
RED
RI6HT DOOR
LOCK SWITCH
-BLACK
7 I
— s •P38 140R/WT*
(RIGHT P35 1 4 0 R / V T *
SIDE P36 1 4 P K / V T *
COWL) b d P2 1 4 B K / W T X - P2 1 4 B K / W T * -
P34 1 4 P K / B K * - P34 14PK/BKX-
12 6 6RAY
( L E F T KICK PANEL)
(SEE
SH 80) FEED TO POWER DOOR
L 0 C K R E L A
(/ S E E SH 79)
? n n R / \ / T * - 4
P35 2 0 0 R / V T X - t \
P35 200R/VT*—] TO POWER DOOR
s
•P36 20PK/VTX— P36 2 0 P K / V T * - { UNLOCK RELAY

1 ( S E E SH 79)
F E E D
D — Ml 20PK
0 FEED TO < M ^ I ] SPLICE
D
Ml 20PK-
' ( S E E SH 4 7 , 4 8 )
R o FEED TO DOME AND
D
MI 2 0 P K - 7 COURTESY
^ LAMP SYSTEM
(SEE SH 48)
8 16 P34 18PK/BKX- P34 1 8 P K / B K * -
P34 18PK/BK*-
P2 18BK/WT*- P2 1 8 B K / W T *
•P2 18BK/WTX-
(RI6HT P35 140R/VT*- P35 140R/VT*-

'B' P34 14PK/BK*- P34 14PK/BKX-
PILLAR) 16 „ 8 8 16
P34 „ TO POWER DOOR
I—18PK ( LOCK RELAY
NATURAL D 0 BK* ( S E E SH 79)
4 DOOR
D 0 FEED
•0 fl | i
ONLY * 0
D fl
F E E D
0 fl pp TO POWER DOOR
0 Q -18BK ( UNLOCK RELAY
BLACK W T * > ( S E E SH 79)
( L E F T KICK PANEL) 9 1
BLACK
XJ 81 POWER DOOR LOCKS J938W-3
P36 14PK/VT*- P34 14PK/BK*—<((
P35 140R/VTX-
P38 14QR/WT*-
P2 14BK/WT* -<f
CLEAR —
P34 14PK/BK*-
P2 14BK/WTX-
P34 14BK/BK*-
i NOTE i
FOR POWER DOOR LOCK A
S W I T C H FUNCTIONS
P2 14BK/WT*-
S E E SH 83
!P34 14PK/BK*
P2 14BK/WT* rate
BLACK
L, .
P2 14BK/WT*-
P34 14PK/BK* •
P34 18PK/BK* <(

E F
P38 14PK/VTX• O O
u P34 18PK/BKX-
P35 140R/VT*- V P2 18BK/WT*-
op w BLACK —'
P38 140R/WT*-
o o X P2 18BK/WT* «-
o o Y BLACK
CLEAR RED M i
P34
o o z P34
-14PK-] I — 14PK - « •
BK* BK*
— J
P34
BODY < P 3 4 18PK- <I LIFTGATE
BK* E> LOCK
P34 18PK/BKX- P2 MOTOR
D
I8BK P2 B
WT*
-14BK-<(
-P2 18BK/WT* - {INSIDE LIFTGATE)
YL*
B0DY<P2
P2 14BK/YL*• P34 14PK/BK*--WraJ^
P34 14PK/BK*" !P35 140R/VT*

P35 140R/VT*- BLACK—' BLACK —
P34 14PK/BK*' L_ ;
P34 14PK/BK * «•
P35 140R/VT* —<£
J938W-3 POWER DOOR LOCKS XJ 82

L E F T FRONT DOOR CONNECTORS

P35 M O R / V T * WINDOW L I F T SWITCH FUNCTION
P36 M P K / V T * AND DOOR LOCK SWITCH FUNCTION
Qll M L B
B + B—
WINDOW MOVEMENT
POLARITY POLARITY
Q21 MWT WT LB L T FRONT UP
P38 MOR/WT* LB WT L T FRONT DOWN
BR/WT* VT/WT* RT FRONT UP
Z l MBK VT/WT* BR/WTX RT FRONT DOWN
Q27 MRD/BK* TN BK FEED AND GROUND

RD/BK* DB/WTX L T REAR UP (4 DOOR ONLY)
DB/WTX RD/BK* L T REAR DOWN (4 DOOR ONLY)
Q17 14DB/WT*
F81 12TN DG/WT* GY/BK* RT REAR UP (4 DOOR ONLY)
Ql M Y L GY/BK* DG/WT* RT REAR DOWN (4 DOOR ONLY)
Q16 14BR/WT*
2
»o o
B + B — DOOR LOCK
H-o o- Q26 MVT/WT*
POLARITY POLARITY FUNCTION ALL DOORS
o o OR/VT* — LOCK
O O PK/VTX — UNLOCK
r-O O Q28 MDG/WT* OR/WTX FEED B +
OO
Q18 HGY/BK*
RIGHT FRONT DOOR LOCK AND SWITCH

CONNECTOR WINDOW L I F T SWITCH FUNCTION
AND DOOR LOCK SWITCH FUNCTION
B + B — WINDOW MOVEMENT
POLARITY POLARITY
BR VT RT FRONT UP(D00R SWITCH)
•P35 MOR/WT*
VT BR RT FRONT D0WN(D00R SWITCH)
2
»o o BR/WT* VT/WT* RT FRONT UP(MASTER SWITCH)
4-o P36 MPK/VT* VT/WT* BR/WT* RT FRONT DOWN(MASTER SWITCH)
O • P38 MOR/WT* YL — FEED
- Q26 MVT/WT*
o o Q22 M V T
o B + B — DOOR LOCK
POLARITY POLARITY FUNCTION ALL DOORS
Q16 M B R / W T *
Q12 M L B OR/VT* — LOCK FROM DOOR SWITCH
Ql M Y L PK/VT* — UNLOCK FROM DOOR SWITCH
OR/WT* — FEED B +
FRONT DOOR LOCK

XJ 83 AND WINDOW SWITCH FUNCTIONS J938H-3
L E F T REAR DOOR WINDOW CONNECTOR

AN WINDOW L I F T SWITCH FUNCTION
B + B— WINDOW MOVEMENT Q22 14VT

POLARITY POLARITY
BR VT L T REAR UP (DOOR SWITCH) Q33 14BR/LB *
VT BR L T REAR DOWN (DOOR SWITCH)
RD/BK* DB L T REAR UP (MASTER SWITCH)
QI2 MBR
DB RD/BK* L T REAR DOWN (MASTER SWITCH)
Q28 MDG/WT*
YL — FEED
RIGHT REAR DOOR WINDOW CONNECTOR

AN WINDOW L I F T SWITCH FUNCTION
B + B — Q22 MVT
POLARITY POLARITY WINDOW MOVEMENT
BR VT RT REAR UP (DOOR SWITCH) Q17 MDB

VT BR RT REAR DOWN (DOOR SWITCH) Ql MYL
DG/WT* BR/LB* RT REAR UP (MASTER SWITCH)
Q12 MBR
BR/LB* DG/WT* RT REAR DOWN (MASTER SWITCH)
Q27 MRD/BK*
YL — FEED
REAR DOOR WINDOW SWITCH FUNCTIONS
POWER MIRROR CONNECTOR

AND SWITCH FUNCTION
-P80 20YL
B + B —
POLARITY WINDOW MOVEMENT -P81 20DB
POLARITY
P79 20DB P80 20YL L E F T MIRROR - UP -P77 2 0 W T / B K *
P80 20YL P79 20DB L E F T MIRROR - DOWN
P79 20DB P78 2 0 Y L / L G * RIGHT MIRROR - UP -P78 2 0 Y L / L G *
P78 2 0 Y L / L G * P79 20DB RIGHT MIRROR - DOWN
ill tail -P60 2 0 B R / W T *
P79 20DB P81 20DB L E F T MIRROR - RIGHT
P81 20DB P79 20DB L E F T MIRROR - L E F T •Zl 20BK
P79 20DB P77 2 0 W T / B K * RIGHT MIRROR - RIGHT -P79 20DB
P77 2 0 W T / B K * P79 20DB RIGHT MIRROR - LEFT
P60 2 0 B R / W T * FEED
Zl 20BK GROUND
J938W-3 POWER MIRROR SWITCH FUNCTIONS XJ 84

8W - 2 2 2 WIRING DIAGRAMS J
TO
FEED
•F12 18DB/WT*-
SPLICE
(SEE SH 16,18)
FEED TO FUEL
AMI MDG/BK*- J PUMP RELAY
^ ( S E E SH 12.17)
FEED TO HEATED
•AMI MDG/BK* ? 0XY6EN SENSOR
^ ( S E E SH 13,21)
FEED TO INSTRUMENT
•64 20DB——I , CLUSTER %
^ ( S E E SH 51)
( L E F T S I D E COWL)
G4 8 16 16 „ 8
AMI
-AMI MDG/BK* MDG 20DB do •64 20DB
-AMI MDG/BK* BK* oo
-K37 2 0 R D / D B * AMI 5 D Q
A241 1 4 D 6 / T N * — 1
18DB MDG 1 0 0
WT* BK* J D
F12 1 8 D B / W T * - D Q
L — • ——M __l
0 Q
-A241 MDG/RD*-
BALLAST
RESISTOR
\
\ V
BY-PASS BLACK-^
RELAY
(RIGHT SIDE
ENGINE
3
COMPARTMENT
ATTATCHED A241
TO POWER MDG
TN*
DISTRIBUTION
TO POWERTRAIN CENTER
C 0
™ H 20RD/DB* A241
(SEE SH 13,21) FEED 141>G
TN*
A241 1 4 D 6 / T N * —i
BALLAST RESISTOR
T 0
( L E F T SIDE REAR SIDE SHIELD)
FEED
FUEL PUMP N
RELAY h
( S E E SH 12.17)
-AMI 14D6/BK*
-QI WSAA-
XJ 85 F U E L TANK SYSTEMS J938W-3

•F9 140R-
-57 16VT-
FUEL
TANK
LEVEL
GAUGE
SENDING
UNIT
-99 18BK
TO
SPLICE ^
( S E E SH 42)
G4 20DB -64 20DB
A241 14DG/RD* -A241 14DG/RD*
a938M-3 F U E L TANK SYSTEMS XJ 86

L90 18DB/RD*
L90 18DB/RD*
L90 18DB/RD*
L90 18DB/RD*
BODY
<^nH] SPLICE5_!HE_ A11 14R0
(SEE SH 74)
LEFT SIDE
L90 20DB/RD*-i
MARKER
Zl 20BK
LAMP
Zl 20BK
L E F T TURN
LAMP L61 20TN
(AMBER)
TAJL
Zl 20BK
LEFT TAIL/
STOP L50 20WT/TN*
LAMP L90 20DB/RD*
Zl 20BK
LEFT
BACK-UP LIO 20BR/LG* ( R E A R OF
L90
LAMP BUMPER)
20DB
(BEHIND RD*
LICENSE PLATE)
LICENSE
LAMP
72 20DB/RD*-
99 2 0 B K -
o*—($13© n~ 3 —
BLACK B L A C K
GND T0<Z1^1]SPLICE
BLACK Z120BK-J {^ 4 2 )
XJ 87 REAR L I G H T I N G WITHOUT T R A I L E R TOW J938H-3

FEED TO LCD
— \ ILLUMINATION RELAY
L90 ( S E E SH 50)
L10 2 0 B R / L G *
18DB
RD*
F E E D
L90 TO FRONT
! 8 D B £ END LIGHTING SYSTEM
( S E E SH 3 7 , 3 8 )
TO HEADLAMP
SWITCH
(SEE SH 39)
TO TURN
SIGNAL SWITCH
(SEE SH 4 3 , 4 4 )
TO ANTI-LOCK
BRAKE SYSTEM
(SEE SH 30)
TO BRAKE
SWITCH
(SEE SH 44)
F E E D ^TO TRANSMISSION
\ CONTROL SYSTEM
(SEE SH 25)
RIGHT SIDE
MARKER
LAMP
RIGHT TURN
LAMP
(AMBER)
RIGHT
TAIL/STOP
LAMP
RIGHT
BACK-UP
LAMP
U938W-3 REAR LIGHTING WITHOUT TRAILER TOW XJ 88

•LIO 2 0 B R / L G * -
GND
TO TRAILER T O < n J l ] SPLICE £ TO T R A I L E R TOW
TOW
(SEE SH 42) HARNESS
(SEE SH 92)
(SEE SH 92)
FEED
L50 18WT/TNX-
L90 18DB/RD*-
LEFT SIDE
MARKER
LAMP
L E F T TURN
LAMP
(AMBER)
LEFT T A I L /
STOP
LAMP
LEFT
BACK-UP
LAMP
LICENSE
LAMP
GND TO < Z 1 > 5 1 SPLICE
Z120BK-5 ( ^ H 4 2 )
XJ 89 REAR LIGHTING WITH TRAILER TOW J938H- 3

WIRING DIAGRAMS BW - 227
J
•L10 20BR/LG*
TO T R A I L E R TOW
RIGHT TURN RELAY
( S E E SH 91)
FEED € TO LCD
L90 1 8 D B / R D * — — ( I L L U M I N A T I O N RELAY
>
( S E E SH 50)
FEED TO FRONT
L90 1 8 D B / R D * (END LIGHTING SYSTEM
>
' S E E SH 3 7 . 3 8 )
TO HEADLAMP
SWITCH
(SEE SH 39)
TO TURN
SIGNAL SWITCH
(SEE SH 43.44)
TO ANTI-LOCK
BRAKE SYSTEM
(SEE SH 30)
TO BRAKE
SWITCH
(SEE SH 4 4 )
FEED , TO TRANMISSION
} CONTROL SYSTEM
(SEE SH 25)
RIGHT S I D E
MARKER
LAMP
RIGHT TURN
LAMP
(AMBER)
~*"~7~~d^ RIGHT
L—4*. y TAIL/STOP
LAMP
RIGHT
BACK-UP
LAMP
J938W-3 REAR LIGHTING WITH T R A I L E R TOW XJ 90

BLACK
TO FUSE
All HRD- PANEL TAP
(SEE SH 93)
FEED
All MRD -(TO POWER SEATS
(SEE SH 74)
IN L I N E
CIRCUIT
BREAKER
10 AMP
BLACK _J—All HRD
(TAPED TO
A l l 16RD
HARNESS " y - BLACK
A l l 16RD BEHIND
•Zl 16BK L E F T REAR J—All 16RD
Z l 16BK PANEL)
94 16DG FEED TO
95 16PK
L50 18WT/TN* i — L50 18WT/TN*-5
1 J , J | | 4 f L\ A
( S E E SH 8 9 , 9 0 ) u
L50 18WT/TN *
A l l 16RD
^ BLACK L50 1 8 W T / T N * - ,
THD L 6 1 18LG/BK %
Ph y — 9 5 16PK
n k L
^ — Z l 16BK BLACK
Z l 16BK (BEHIND « F E E D
95 16PK
L E F T REAR Alttv
94 16DG PANEL) TO BRAKE
SWITCH AND
Ml - L 6 0 18TN
94 16DG
ANTI-LOCK g ^ J ^ Z l 16BK
L S I 18LG BRAKES ^ " ^ > 95 1 6 P K
(SEE SH 89) •94 16DG
-L60 18TN/DG* I
. TO REAR LAMPS . i 4
A AND TURN SIGNAL V
>
> SWITCH
F E E D
( S E E SH 90)
94 16DG
95 16PK
(BEHIND '
L E F T REAR (BEHIND
PANEL) L E F T REAR
PANEL)
Z l 16BK
L60 18TN
L61 18LG/BK*
Z l 16BK Zl 16BK -€b- Zl HBK
(SEE SH 42)
XJ 91 T R A I L E R TOW J938H-3
TO PROVISION
FOR ELECTRIC
TO BACK-UP TRAILER BRAKES
LAMP SYSTEM SPLICE
[SEE SH 89) (SEE SH 89) FEED
FEED
FEEDT "JFI
L10 L10
20BR 20BR
LG* LG*
GREEN
(BEHIND LEFT
REAR PANEL)
All 16RD-
L61 L60 Zl All

HRD
lie* ™ 18
HBK
CLASS I I I (C)
L60
18TN
L60 18TN
L61 18LG/BK*-
- Z l HBK
J938M-3 TRAILER TOW XJ 92

F87
20WT G i l Zl G10
B K * 20WT 18BK 18LG
F83 F87 Mil L7
18YL L5 20WT 20PK Zl 18BK
BK* 18BK BK* LB* 18BK YL*
"ST CHIME
MODULE
TU TU Hi TU
TURN SIGNAL
•V15 18LB/RD*
FLASHER
A38 120R/WT*
F85 18VT/HT*
A48 12VT
1
A48 12VT/BR*
WINDOW > 12TN
TAP C7 1 2 B K / T N *
Ml 20PK
Lll 16PK/LG*
A3 12RD/0R* F83 1 8 Y L / R D *
A38 120R/VT* F83 1 8 Y L / B K *
236 18LG/YL*
(ABS) j
A6 12RD/DB*
X4 166Y/0R*
A38 120R
A38 120R/WT*
~L X4
L7
166Y/0R*
18BK/0R*
P37 18LG- A3 12RD/WT*
A7 12RD/YL*
ri_n F87 2 0 W T / B K *
TZT
7.5#3 A2 12DB
16 F87 2 0 W T / B K *
J w
17
A7 1 2 R D / Y L *
INST LPS
HAZARD FLASHER
All E2 2 0 0 R / B K *
14RD L9 1 6 P K / B K *
HTLV
WDW L9 1 6 P K / B K *
L12 1 8 V T / T N *
E2 200R/D6*
POWER SEAT TAP F81 A4
(INCLUDES 30 AMP 12BR12BK
CIRCUIT BREAKER AS RD*
PART OF TAP
ASSEMBLY)
XJ 9 3 F U S E PANEL J938W-3
FUSE
NUMBER AMPS COLOR SHEET
1 25 WHITE 2,10,61
2 15 L I 6 H T BLUE 2.9.35.67
3
4
—
15
—
LIGHT BLUE
—
1.39
5 25 WHITE 2.59.60.64.66
—
6
7
—2 —
PINK 2.10.30
8 20 YELLOW 2.43.62
9 10 RED 1.4,47
10
11
—
25
— _
WHITE
—
1.41,79
—
12
13 20
—
YELLOW
—
79
14
15
—15
—
LIGHT BLUE
—
1,39
16
17
—
7.5
—
BROWN
—
2,10.51.70
18 25 WHITE 1.62
19 5 TAN 1.39.45
J938W-3 F U S E PANEL XJ 94
CAV CIRCUIT FUNCTION SHEET

Al LSI 18LG L E F T FRONT TURN SIGNAL 37,43
A2 K54 2 0 0 R / B K * U P S H I F T INDICATOR LAMP 51
A3 F36 I 3 L G / B K * FUSED IGNITION ' C 59,60
A4 L9 18BK/WT* HAZARD FLASHER FEED 4,33,44
AL C90 16LG A/C SELECT SIGNAL 65
AS A6 1 8 R D / B K * BATTERY FEED 4,47
A7 G3 2 0 B K / P K * MALFUNCTION INDICATOR LAMP 51
Bl L90 1 8 D B / R D * PARK LAMP FEED 37,39,50,88,90
B2 V10 20BR WINDSHIELD WASHER PUMP FEED 59,60
B3 V4 I 8 R D / Y L * WINDSHIELD WIPER ( H I SPEED) 59.60
B4 G21 2 0 G Y / L 8 * TACHOMETER SIGNAL 51
B5
B6 A21 12DB IGNITION S T A R T / R U N 10.12
CI 107 2 0 B K / R D * 4 WHEEL LOCK LAMP 26.52
C2
C3
BLACK
C4 A241 14DG/TN* BALLAST RESISTOR 85
C4 A241 1 4 D 6 / T N * BALLAST RESISTOR RELAY 85
C5 L10 1 8 B R / L 6 * BACK-UP LAMP FEED 25,88.90
C6 G6 20GY ENGINE OIL PRESSURE INDICATOR 24,51
01 A3 12RD/WT* HEADLAMP SWITCH FEED 4.39
02 A4 128K/RD* HEATED REAR WINDOW FEED 62
05 L4 16VT/WT* HEADLAMP (LOW BEAM) 37
D5 L4 14VT/WT* HEADLAMP (LOW BEAM) 37
El A7 1 2 R D / Y L * BATTERY FEED 4.41.79
E2 X2 18DG/RD* HORN FEED 32
E2 X2 18DG/RDX HORN FEED 32
••••••• E4
E5
Al 10RD
CI 12DG
IGNITION SWITCH FEED
BLOWER MOTOR FEED 64.66
3^
A B C D E F 6 H
F!
Fl
465 1 6 L B / B K *
L3 16RD/0R*
HIGH BEAM INDICATOR W/DRL
HIGH BEAM INDICATOR W/0 DRL
36.38.51
38.51
F2 L60 18TN RIGHT FRONT TURN SIGNAL 38.43
F3 620 1 8 V T / Y L * ENGINE COOLANT TEMPERATURE 9.24.51
VIEWED FROM TERMINAL END
F4 G9 20GY/WT* BRAKE WARNING LAMP SWITCH 63
F5 69 20GY/BK* BRAKE WARNIN6 LAMP SWITCH 63
Gl L35 1 6 B R / W T * FOG LAMP RELAY 38.40
G2 612 2 0 D 6 / Y L * CHECK GAU6E LAMP 51
G3 V3 18BR/WT* WINDSHIELD WIPER (LOW SPEED) 59.60
G4 Z l 12BK 6R0UND 40,59,60
G5 C91 16LB A/C REQUEST 65
HI C21 16DB/0RX A/C PRESSURE SWITCH 65
H2 A41 H Y L ENGINE S T A R T E R RELAY 7,9
H3 V55 18TN/RD* WINDSHIELD W I P E R (PARK SIGNAL 59,60
H4 L3 1 6 R D / 0 R * HEADLAMP (HIGH BEAM) 37.39
H4 L3 HRD/OR* HEADLAMP (HIGH BEAM) 37
H5 V20 18BK/WT* REAR WASHER FEED 61
H6 G29 2 0 B K / T N * LOW WASHER F L U I D LEVEL INDICATOR 51
45-WAY BULKHEAD DISCONNECT

XJ 95 (2.5L ENGINE) J938W-3
J WIRING DIAGRAMS 8W • 233

Al LSI 18LG L E F T FRONT TURN SIGNAL 37.43
Al L61 18LG L E F T FRONT TURN SIGNAL 37.4.3
A2 K54 20LG/0R* UPSHIFT INDICATOR LAMP 51
A3 F86 18LG/BK* FUSED IGNITION ' C 59.60
A4 L9 16PK/BK* HAZARD FLASHER FEED 4.33.44
A5 C90 16LG/WTX A/C SELECT SIGNAL 65
A6 AS 12RD/DB* BATTERY FEED 4.47
A7 G3 20BK/PK* MALFUNCTION INDICATOR LAMP 51
Bl 190 18DB/RD* PARK LAMP FEED 37.39.50.
Bl L90 18DB/RD* PARK LAMP FEED 88.90
B2 V10 20BR WINDSHIELD WASHER PUMP FEED 59.60
B3 V4 18RD/BK* WINDSHIELD WIPER (HIGH SPEED) 59.60
B4 G21 20GY/LB* TACHOMETER SIGNAL 51
B5
B6
—
A21 1 2 D B / Y L *
—
IGNITION START/RUN 10.12
—
CI 107 2 0 B K / L B * 4 WHEEL LOCK LAMP 26.52
C2 02 18WT/BK* SERIAL BUSS ( B —) 25.30
C2 02 18WT/BK* SERIAL BUSS ( B — ) 25.30
C3 Dl 1 8 V T / B R * SERIAL BUSS (B + ) 25.30
C3 Dl 1 8 V T / B R * SERIAL BUSS ( B + ) 25.30
C4 A241 14DG/TN* BALLAST RESISTOR RELAY 85
C5 L10 1 8 B R / L G * BACK-UP LAMP FEED 25.88.90
C6 G6 20GY ENGINE OIL-PRESSURE INDICATOR 24.51
Dl A3 12RD/WT* HEADLAMP SWITCH FEED 4.39
02 A4 12BK/RDX HEATED REAR WINDOW FEED 62
05 L4 16VT/WT* HEADLAMP (LOW BEAM) 37
E2 X2 16D6/RD* HORN FEED 32
E4 Al 12RD IGNITION SWITCH FEED 9
E5 CI 12DG BLOWER MOTOR FEED 64.66
Fl L3 16RD/YL* HEADLAMP (HIGH BEAM) 36.38.51 VIEWED FROM TERMINAL END
F3 G20 2 0 V T / Y L * ENGINE COOLANT TEMPERATURE 9.24.51
F3 G20 2 0 V T / Y L * ENGINE COOLANT TEMPERATURE 9.24.51
F4 G9 18GY/0R* BRAKE WARNING LAMP SWITCH 63
F5 G9 2 0 6 Y / W T * BRAKE WARNING LAMP SWITCH 63
Gl L35 16BR/WT* FOG LAMP RELAY 38.40
G2 G12 2 0 D 6 / B K * CHECK GAUGE LAMP 51
G3 V3 1 8 B R / T N * WINDSHIELD WIPER (LOW SPEED) 59.60
G4 Z l 12BK GROUND 40 5 9 , 6 0
G5 C91 16LB A/C REQUEST 65
G6 A38 120R IGNITION RUN 10
HI C21 16DB/0R* A/C PRESSURE SWITCH 65
H2 A41 MYL ENGINE STARTER RELAY 7,9
H3 V55 1 8 T N / R D * WINDSHIELD WIPER (PARK SIGNAL) 59,60
H5 V20 18BK/WT* REAR WASHER PUMP MOTOR FEED 61
H6 G29 20BK/TN* LOW WASHER F L U I D LEVEL INDICATOR 51

( 2 . 5 L ENGINE)
J938W-3 XJ 96

Al L 6 1 18LG L E F T FRONT TURN SIGNAL 37,43
A2 K54 20LG/0R * UPSHIFT INDICATOR LAMP 51
A3 F88 18LG/BK* FUSED IGNITION ' C 59,60
A4 L9 1 8 B K / W T * HAZARD FLASHER FEED 4,33,44
AS C90 16LG A/C SELECT SIGNAL 65
A6 A6 18RD/BKX BATTERY FEED 4.47
A7 63 2 0 B K / P K * MALFUNCTION INDICATOR LAMP 51
Bl L90 1 8 D B / R D * PARK LAMP FEED 37.39.50.88,90
82 V10 20BR WINDSHIELD WASHER PUMP FEED 59.60
B3 V4 18RD/YL % WINDSHIELD WIPER (HIGH SPEED) 59,60
84 621 2 0 G Y / L 8 * TACHOMETER SIGNAL 51
85 106 2 0 8 K / Y L * 4 WHEEL DRIVE SWITCH 26,52
B6 A21 12DB IGNITION START/RUN 10,17
CI 107 2 0 B K / R D * 4 WHEEL LOCK LAMP 26.52
CI 107 20BK/RD * 4 WHEEL LOCK LAMP 26
C2
C3
C4 A241 14D6/TNX BALLAST RESISTOR 85
C4 A241 1 4 D 6 / T N * BALLAST RESISTOR RELAY 85
C5 L10 18BR/LGX BACK-UP LAMP FEED 25.88.90
C6 G6 20GY ENGINE OIL PRESSURE INDICATOR 24.51
Dl A3 12RD/WTX HEADLAMP SWITCH FEED 4.39
D2 A4 1 2 B K / R D * HEATED REAR WINDOW FEED 62
05 L4 16VT/WTX HEADLAMP (LOW BEAM) 37
D5 L4 1 4 V T / W T * HEADLAMP (LOW BEAM) 37
E2 X2 18D6/RD* HORN FEED 32
E2 X2 18DG/RDX HORN FEED 32
E4 Al 10RD IGNITION SWITCH FEED
E5 CI 12DG BLOWER MOTOR FEED 64.66
Fl 465 16LB/BKX HIGH BEAM INDICATOR W/DRL 36.38,51
Fl 634 1 6 R D / 6 Y * HIGH BEAM INDICATOR W/0 DRL 38.51
A B C D E F 6 H
F2 L60 18TN RIGHT FRONT TURN SI6NAL 38,43
F3 620 1 8 V T / Y L X EN6INE COOLANT TEMPERATURE 9.24.51
F4 G9 206Y/WTX BRAKE WARNING LAMP SWITCH 63
F5 69 2 0 6 Y / B K * BRAKE WARNING LAMP SWITCH 63
F6 KIO 18VT IDLE INCREASE (POLICE)" 17
61 L35 1 6 B R / W T * F06 LAMP RELAY 38.40
62 612 2 0 D 6 / Y L * CHECK GAUGE LAMP 51
G3 V3 18BR/WTX WINDSHIELD WIPER (LOW SPEED) 59.60
64 Z l 12BK GROUND 40.59,60
65 C91 16LB A/C REQUEST 65
HI C21 1 6 D B / 0 R * A/C PRESSURE SWITCH 65
H2 A41 H Y L ENGINE STARTER RELAY 8.9
H3 V55 1 8 T N / R D * WINDSHIELD WIPER (PARK SIGNAL) 59.60
H4 L3 HRD/OR* HEADLAMP (HIGH BEAM) 37
H6 G29 20BK/TNX LOW WASHER F L U I D LEVEL INDICATOR 51

XJ 97 ( 4 . 0 L ENGINE) J938W-3

Al L61 18L6 L E F T FRONT TURN SI6NAL 37.43
Al L61 18L6 L E F T FRONT TURN SI6NAL 37,43
A2 K54 2 0 L 6 / 0 R X UPSHIFT INDICATOR LAMP 51
A3 F86 1 8 L 6 / B K * FUSED IGNITION ' C 59,60
A4 L9 1 6 P K / B K * FLASHER FEED 4,33,44
A5 C90 1 6 L 6 / W T * A/C SELECT SIGNAL 65
A6 A6 12RD/DB % BATTERY FEED 4,47
A7 G3 2 0 B K / P K * MALFUNCTION INDICATOR LAMP 51
Bl L90 1 8 D B / R D * PARK LAMP FEED 37,39,50
Bl L90 1 8 D B / R D * PARK LAMP FEED 88,90
B2 V10 20BR WINDSHIELD WASHER PUMP FEED 59,60
B3 V4 18RD/BK % WINDSHIELD WIPER (HIGH SPEED) 59,60
B4 G21 2 0 6 Y / L B * TACHOMETER SIGNAL 51
B5 106 2 0 B K / Y U F U L L TIME INDICATOR LAMP 26,52
B6 A21 1 2 D B / Y U IGNITION START/RUN 10,17
CI 107 2 0 B K / L B * 4 WHEEL LOCK LAMP 26,52
C2 02 18WT/BKX SERIAL BUSS ( B —) 21,25,30
C2 02 18WT/BKX SERIAL BUSS ( B —) 21,25,30
C3 Dl 1 8 V T / B R * SERIAL BUSS ( B + ) 21,25,30
C3 Dl 1 8 V T / B R * SERIAL BUSS ( B + ) 21,25,30
C4 A241 14D6/TNX BALLAST RESISTOR RELAY 85
C5 LiO 1 8 B R / L 6 * BACK-UP LAMP FEED 25,88,90
C6 66 206Y ENGINE O I L - P R E S S U R E INDICATOR 24,51
01 A3 12RD/WT * HEADLAMP SWITCH FEED 4,39
02 A4 12BK/RD % HEATED REAR WINDOW FEED 62
D5 L4 16VT/WT % HEADLAMP (LOW BEAM) 37
El hi 12RD/YL % BATTERY FEED 4,41,79
E2 X2 16DG/RD % HORN FEED 32
E5 CI 12DG BLOWER MOTOR FEED 64,66
36,38,51 VIEWED FROM TERMINAL END
Fl L3 16RD/YL * HEADLAMP (HIGH BEAM)
F2 L60 18TN RI6HT FRONT TURN SIGNAL 38,43
F2 L60 18TN RI6HT FRONT TURN SIGNAL 38,43
F3 620 2 0 V T / Y L % ENGINE COOLANT TEMPERATURE 9,24,51
F3 620 2 0 V T / Y L * ENGINE COOLANT TEMPERATURE 9,24,51
F4 69 1 8 6 Y / 0 R * BRAKE WARNING LAMP SWITCH 63
F5 69 2 0 6 Y / W T * BRAKE WARNING LAMP SWITCH 63
Gl L35 1 6 B R / W T * FOG LAMP RELAY 38,40
62 612 2 0 D 6 / B K * CHECK GAU6E LAMP 51
63 V3 18BR/TN X WINDSHIELD WIPER (LOW SPEED) 59,60
64 Z l 12BK GROUND 40,59,60
65 C91 16LB A/C REQUEST 65
66 A38 120R IGNITION RUN 10
HI C21 16DB/0R X A/C PRESSURE SWITCH 65
H2 A41 H Y L ENGINE STARTER RELAY 8,9
H3 V55 18TN/RD X WINDSHIELD WIPER (PARK SIGNAL) 59,60
H4 L3 16RD/0R * HEADLAMP (HIGH BEAM) 37,39
H5 V20 1 8 B K / W T * REAR WASHER PUMP MOTOR FEED 61
H5 V20 18BK/WT X REAR WASHER FEED 61
H6 629 2 0 B K / T N * LOW WASHER F L U I D LEVEL INDICATOR 51

( 4 . 0 L ENGINE)
J938W-3 XJ 98
CI — — —
C2 — — —
C3 505 1 8 T N / B K * TRANSMISSION OUTPUT SPEED SENSOR 26
C4 137 16YL/BK* TRANSMISSION DATA LINK CONNECTOR 25
C5 — — —
C6 — — —
C7 — — —
BLACK C8 506 18L6/BKX 1-2 GEAR INPUT 25
C9 507 186Y/BK* D R I V E GEAR INPUT 25
01 • • CI CIO K29 18WT/PK X BRAKE S E N S E SIGNAL 26
Cll 111 20TN TRANSMISSION SWITCH POWER MODE 26
C12 — — —
C13 — — —
C14 508 18WT/BK X TRANSMISSION SOLENOID 26
i3 C15 509 18VT/WTX SOLENOID S2 26
C16 510 18DB/WTX SOLENOID SI 26
Dl — — —
D2 180R/DB X THROTTLE POSITION (SENSOR) 26

9 D3
K22
K4 18BK/LBX SENSOR GROUND 26
04 — — —
D5 — — —
D6 — — —
D1GDDC16 D7 Z12 1 8 B K / T N X POWER GROUND 26
08 — — —
09 — — —
V I E W E D FROM T E R M I N A L END
010 — — —
Oil — — —
D12 — — —
D13 — — —
D14 A14 HRD AUTOMATIC S H U T DOWN R E L A Y 26
D15 — — —
016 T17 18YL MODULE F E E D (IGNITION) 25
TRANSMISSION CONTROL MODULE (TCM)

CONNECTOR
XJ 99 J938H-3
D E F G H J K L M N P
J
1
K iL M N nP
IT-
VIEWED FROM T E R M I N A L END
P — — -
N L60 18TN/DG X RIGHT REAR TURN SIGNAL 44
M L61 18LG/BK X L E F T REAR TURN SIGNAL 44
L L5 I8BK TURN SIGNAL FLASHER 44
K L12 18VT/TN X HAZARD FLASHER 44
U L60 18TN RIGHT FRONT TURN SIGNAL 44
H L61 18LG L E F T FRONT TURN SIGNAL 44
G X3 20BK/RD X HORN SWITCH 32
F Mil 20PK/LB X SWITCHED COURTESY LAMP FEED 70
E G26 20LB IGNITION KEY WARNING SWITCH 70
D — — —
J938W-3 S T E E R I N G COLUMN CONNECTOR XJ 100


1 G29 20BK/TNX LOW WASHER F L U I D LEVEL INDICATOR 52
2 63 2 0 B K / P K * MALFUNCTION INDICATOR LAMP 52
NATURAL 3 F87 20WT/OR* FUSE IGNITION ' D ' 52
3 F87 20WT/BK* FUSE IGNITION ' D ' 52
4 F87 20WT/BKX FUSE IGNITION ' D ' 52
4 F87 20WT/BKX FUSE IGNITION 'D' 52
5 — — —
6 205 18YL ABS YELLOW LAMP 52
7 K54 20LG/OR* U P S H I F T INDICATOR LAMP 52
8 203 18DG BRAKE PRESSURE/PARK BRAKE LAMP 52
9
10 Ml 20PK
— COURTESY LAMP
— 52
—
11 106 20BK/YLX 4WD SWITCH 52
12 107 2 0 B K / L B * 4WD LOCK LAMP 52
VIEWED FROM TERMINAL END 13 G24 20GY/PKX MAINTENANCE INDICATOR LAMP 52
14 F87 20WT/BK X FUSE IGNITION ' D ' 52
15 611 20WT SEAT B E L T LAMP 52
16 Z l 20BK GROUND 52
16 Z l 20BK 6R0UND 52
XJ 101 TELLTALE CONNECTOR J938H-3


Al 620 2 0 V T / Y L *
EN6INE COOLANT TEMPERATURE 51
A2 L61 18L6 L E F T TURN INDICATOR LAMP 51 r-BLACK
A3 Z l 20BK GROUND 51
A4 HEADLAMP (HIGH BEAM)
L3 1 6 R D / Y L * 51 • 1 A8
B8l
A5 67 2 0 W T / 0 R *
VEHICLE SPEED SIGNAL 51 • O
A6 G21 20GY/LBX TACHOMETER SIGNAL 51 OO
hi PANEL ILLUMINATION
E2 2 0 0 R / B K * 51 oo
DO
A8 F87 2 0 W T / B K *
FUSED IGNITION 'D' 51 OO
DO
Bl 64 200B FUEL 6AU6E 51 DO
— — DO
B2 —
Bl Al
— —
B3
B4
—
— — —
B5 — — —
B6 L60 18TN RI6HT TURN INDICATOR LAMP 51
B7 66 206Y EN6INE OIL PRESSURE INDICATOR 51
68 612 20D6/BK * CHECK 6AU6E LAMP 51
J938W-3 INSTRUMENT CLUSTER CONNECTOR XJ 102


1 Zl HBK GROUND 31
2 B243 16D6/BKX LEFT FRONT DELAY VALVE 31
3 235 146Y/YL % SOLENOID (12 VOLTS) 31
15 B l 1 6 186Y PUMP RELAY COIL (B-) 29
16 B258 186Y/LBX TRANSDUCER FEED ( + ) 28
19 Z l HBK GROUND 31
20 B245 16WT/L6 %LEFT FRONT ISOLATE VALVE 31
21 B248 16D6/WT* RIGHT FRONT DELAY VALVE 31
% 23 Dl 18VT/BR % SERIAL BUSS (B + ) 30
M l 25 515 18YL/VT* ACCEL SENSOR 28
26 517 18PK/0R % ACCEL SENSOR 28
• " I % 27 B2 18YL RIGHT REAR WHEEL SENSOR (+) 27
% 28 B3 16L6/DB* LEFT REAR WHEEL SENSOR ( —) 27
% 29 B6 18WT/D8* RIGHT FRONT WHEEL SENSOR (—) 27
% 30 68 18RD/DB* LEFT FRONT WHEEL SENSOR ( — ) 27
% 31 B219 18D6 BOOST PRESSURE 28
M l
32 L50 18WT/TN % STOP LAMP FEED 30
33 235 146Y/YLX SOLENOID (12 VOLJS) 31
34 207 18PK ABS RELAY #1 29
36 B254 16DG/0R* RIGHT AND LEFT REAR DELAY VALVE 31
38 8249 16WT/TN %RI6HT FRONT ISOLATE VALVE 31
41 B210 18RD/BK* TRANSDUCER RETURN (—) 28
%
42 D2 18WT/BK* SERIAL BUSS (B-) 30
138 20 \ 43 516 18TN/WT* ACCEL SENSOR 28
%
45 Bl 18YL/DB* RI6HT REAR WHEEL SENSOR ( —) 27
% 46 14 18L6 LEFT REAR WHEEL SENSOR (+) 27
• %
%
47
48
B7 18WT
89 18RD
RI6HT FRONT WHEEL SENSOR ( + )
LEFT FRONT WHEEL SENSOR (+)
27
27
VIEWED FROM T E R M I N A L END % 49 8220 18TN BOOST PRESSURE RETURN 28
52 205 18VT YELLOW LAMP 30
53 236 18L6/YL* IGNITION (12 VOLTS) 30
54 B251 16WT/BK* LEFT REAR ISOLATE VALVE 31
* INDICATES TWISTED PAIRS D1*D2,B1*B2,B3*B4,B6.B7,B8*89,B219*B220
ANTI-LOCK BRAKE
XJ 103
CONTROL MODULE CONNECTOR J938W-3
BLACK
P80 20YL
CAV CIRCUIT FUNCTION SHEET P81 20DB
A P80 20YL UP/DOWN MOTOR ( L E F T ) 69 P77 2 0 W T / B K *
8 P81 20DB R I G H T / L E F T MOTOR ( L E F T ) 69
C P77 20WT/BKX R I G H T / L E F T MOTOR (RIGHT) 69 1
0 P78 2 0 Y L / L G * UP/DOWN MOTOR (RIGHT) 69

fflUffiLE ©—P78 20YL/L6*
E P79 20DB MIRROR RETURN 69 Dpf TE^J3D|— P38 200R/WT*

F Z l 20BK GROUND 69
G P38 2 0 0 R / W T * MIRROR FEED (B+) 69 Z l 20BK
P79 20DB
VIEWED FROM TERMINAL ENO
J938W-3 POWER MIRROR CONNECTOR XJ 104


1 Kl 2 0 D 6 / R D * MAP SENSOR 14,19
2 K2 2 0 T N / B K * ENGINE COOLANT TEMPERATURE SENSOR 14.19
3 A14 H R D AUTOMATIC SHUT DOWN RELAY 12.17
4 K4 1 8 B K / L B * SENSOR GROUND 14.19
5 Z l l 16BK/WTX SIGNAL GROUND 16.18
r
6 ~ 1 K6 2 0 V T / W T * 5 VOLT SUPPLY H,19
7 K7 180R 8 VOLT SUPPLY 11.20
—
8
9 A21 H D B
—
IGNITION START/RUN
—
12.17
10 K10 1 8 D B / W T * POWER STEERING SWITCH (2.5L) 15.17
11 POWER GROUND 13.21
Z12 16BK/TN t
12 Z12 1 6 B K / T N * POWER GROUND 13.21
13 K H 18LB/BR* INJECTOR 4 15.22
M 14 K13 1 8 Y L / W T * INJECTOR 3 15,22
ft 15 K12 18TN INJECTOR 2 h.5.22 J
16 K l l 18WT/DB * INJECTOR 1 15,22
«e
W
? 17
18
— —
—
—
OT
19
—
K19 186Y IGNITION COIL DRIVER # 1 16,18 '
ce 20 K20 18DG VOLTAGE REGULATOR M3.20
r*.
21 K21 18BK/RDX INTAKE AIR TEMPERATURE SENSOR
nr.
14,19
is
« 22 K22 1 8 0 R / D B * THROTTLE POSITION (SENSOR)
m 23
24
—
K24 18GY/BK *
—
DISTRIBUTOR IGNITION SENSOR
—
11,20
m
8 25 D21 20PK SERIAL COMMUNICATION INTERFACE 16,3 8
©
8 26 Dl 1 8 V T / B R * SERIAL BUSS B + ( 4 . 0 L AUTO ONLY) 2!
——^ C91 16LB A/C REQUEST 65
28 C90 16LG A/C SELECT [65
(O) 29
30
31
32
K29 1 8 W T / P K *
T41 1 8 B R / Y L *
C27 20DB/PKX
63 20BK/PK t
BRAKE SENSE SIGNAL
NEUTRAL SENSE (A/TRANS ONLY)
COOLING FAN ( 4 . 0 L ONLY)
MALFUNCTION INDICATOR LAMP
43
21
23
51
33 V36 2 0 T N / R D * VEHICLE SPEED CONTROL (VACUUM) 34
m 34 C13 2 0 D B / 0 R * A/C COMPRESSOR CLUTCH RELAY COIL GROUND 65
—
CJj
ft 35
36 G12 20DG/YL *
—
CHECK GAUGE LAMP
—
51
ft 37 K37 2 0 R D / D B * BY-PASS RELAY 13,21
R
£ 38 K15 1 8 P K / B K * INJECTOR 5 ( 4 . 0 L ONLY) 22
in 39 K39 18GY/RD* IDLE AIR CONTROL (OPEN) 15,22
ft 40 K40 1 8 B R / W T * IDLE AIR CONTROL (CLOSE) )5,22 ^
J© « 41 K41 1 8 B K / D 6 * HEATED OXYGEN SENSOR INPUT 13.21
Hi
(r,
42
43
—
621 2 0 6 Y / L B *
—
TACHOMETER SIGNAL
—
51
S 44 K44 1 8 T N / Y L * CAMSHAFT POSITION SENSOR 11.20
45 D20 20L6 SERIAL COMMUNICATION INTERFACE 16,18
2
* 46 02 1 8 W T / B K * SERIAL BUSS B — ( 4 . 0 L AUTO ONLY) 21
8 47 G7 2 0 W T / 0 R * VEHICLE SPEED SENSOR SIGNAL 11,20
48 V31 2 0 B R / R D * VEHICLE SPEED CONTROL ( S E T ) 33
49 V32 2 0 Y L / R D * VEHICLE SPEED CONTROL (IGNITION) 33.43
50 V33 2 0 W T / L G * VEHICLE SPEED CONTROL (RESUME)
51 K51 2 0 D B / Y L * AUTOMATIC SHUT DOWN RELAY
VIEWED FROM W I R E END 52 —
53
—
V35 2 0 L G / R D *
—
VEHICLE SPEED CONTROL (VENT) 34
54 K54 200R/BKX U P S H I F T INDICATOR LAMP 51
— —
* INDICATES TWISTED PAIR
55
56 624 2 0 6 Y / P K *
—
MAINTENANCE INDICATOR LAMP
57 A142 1 8 D 6 / 0 R * INJ/SENSE/GENERATOR FEED 15.22
58 K16 1 8 L 6 / B K * INJECTOR 6 ( 4 . 0 L ONLY) 22
59 K59 1 8 V T / B K * IDLE AIR CONTROL (CLOSE) 15.22 j
60 K60 1 8 Y L / B K * IDLE AIR CONTROL (CLOSE) 15.22
XJ 105 POWERTRAIN CONTROL MODULE ( P C M ) CONNECTORjsasu-a

J WIRINe DIAGRAMS 8W - 243

1 X58 18DB/0R* RI6HT REAR SPEAKER ( B - ) 67
-GRAY^
2 X52 1 8 D B / W T * R I 6 H T REAR SPEAKER (B + ) 67
3 E2 2 0 0 R / B K * PANEL ILLUMINATION 46
IS 16 D a 4 Zl 14BK 6R0UND 40
D
D a 5 Ml 20PK COURTESY LAMP 48,81
D a
6 X57 18BR/LB* L E F T REAR SPEAKER (B-) 67
= D a
D a 7 X51 18BR/YL* L E F T REAR SPEAKER (B + ) 67
0 a 9 M2 20YL SWITCHED 6R0UND 48
D a 10 GIO 18LG SEAT B E L T SWITCH 70
D 0 D
11 V13 1 8 B R / R D * REAR WIPER RUN 61
12 F20 18WT REAR WIPER PARK 61
VIEWED FROM TERMINAL END 13 P35 2 0 0 R / V T X RELAY (LOCK) 81

14 P36 2 0 P K / W T * RELAY (UNLOCK) 81
-BLACK> CAV CIRCUIT FUNCTION SHEET

1 A241 14D6/TNX FUEL PUMP 85
2 L60 18TN/DG t RIGHT REAR TURN SIGNAL 88,90
16 16 D
3 L90 18DB/R0 * PARK LAMP FEED 88,90
D
3 L90 18DB/RD* PARK LAMP FEED 88,90
1° 4 G4 20DB FUEL GAUGE 85
1°
P°
5
6
L10
L61
18BR/LG*
18LG/BKX
BACK-UP LAMP FEED
L E F T - R E A R TURN SIGNAL
88,90
88,90
L 0
D 7 69 18GY/0R* BRAKE WARNING LAMP SWITCH 63
7 203 18DG BRAKE PRESSURE/PARK BRAKE LAMP 63
8 CIS 12BK/RD * HEATED REAR WINDOW FEED 62
VIEWED FROM TERMINAL END 10 ¥20 1 3 B K / W T * REAR WASHER FEED 61
11 LSO 1 8 W T / T N * STOP LAMP FEED 88,90
11 LSO 1 8 W T / T N * STOP LAMP FEED 88,90
12 P2 18BK/WT * RELAY TO POWER LOCK MOTOR 81
13 P34 1 8 P K / B K * DOOR LOCK MOTOR B * UNLOCK 81
J938H-3 MAIN BODY CONNECTORS XJ 106

8 W - 244 WIRING DIAGRAMS J
POWER DOOR POWER DOOR LCD ILLUMINATION

LOCK RELAY UNLOCK RELAY RELAY
CAV CIRCUIT INFORMATION CAV CIRCUIT INFORMATION CAV CIRCUIT INFORMATION
Al P2 18BK/WT* Bl P34 1 8 P K / B K * Cl X5 18LB/gQ_jL
A2 P37 18LG B2 P37 18LG C2 E2 2 0 0 R / B K *
A2 P37 18LG B3 P36 20PK/VTX C3 Z l 18BK
A3 P35 200R/WTX B4 Z l 18BK C4 F85 18VT/WT*
A4 Z l 18BK B4 Z l 18BK C5 LSO 18DB/RD*
A4 Z l 18BK B5 Z l 18BK LOCATION C
A5 Z l 18BK LOCATION B
A5 Z l 18BK
LOCATION A
HEATED REAR
WINDOW RELAY HORN RELAY
CAV CIRCUIT INFORMATION CAV CIRCUIT INFORMATION
HI C15 12BK/RDX Jl X4 16GY/PKX
H2 Z l 18BK J2 X3 2 0 B K / R D *
H3 C80 1 8 D B / W T * J4 X2 16DG/RD*
H4 F81 12BR J5 X4 16GY/PK*
H5 F83 18YL/RDX J5 X4 16GY/PKX
LOCATION H LOCATION J
2 SB 2 M TO
F l
3 4 3 4
i ^ 2
2
Em
H 5
ffl 13 4
A
5 r
3 4 5 u
3 4 5
am
i
2 p
3 4
i 3 4
mm
M 2 « 2
m
« 2
u
3 4 5 3 4 5
TT
XJ 107 RELAY CENTER IDENTIFICATION J938W-3

J H E A T I N G AND A I R CONDITIONING 24 - 1
HEATING AND AIR CONDITIONING
CONTENTS
page page
C L I M A T E CONTROL S Y S T E M - X J V E H I C L E S . 26 SERVICE DIAGNOSIS-ELECTRICAL 14

CLIMATE CONTROL S Y S T E M - Y J VEHICLES . 41 SERVICE DIAGNOSIS-MECHANICAL 8
COMPRESSOR OVERHAUL 17 TORQUE SPECIFICATIONS 49
GENERAL INFORMATION 1
GENERAL INFORMATION
INDEX
page page
A/C Operation 1 Service Valves 3
Compressor Oil Level 6 System Charge 5
Pressure Gauge and Manifold Assembly 2 System Discharge 4
Refrigerant 1 System Evacuation 4
Service Precautions 2
A/C O P E R A T I O N T E M . IF E Y E CONTACT I S MADE, A P P L Y A F E W

The compressor increases the pressure and temper DROPS OF MINERAL OIL T O THE E Y E S AND F L U S H
ature of the refrigerant. The heated refrigerant vapor WITH WATER FOR S E V E R A L MINUTES. S E E K MEDI
is then pumped into the condenser where it cools by CAL A T T E N T I O N IMMEDIATELY.
the air passing over the condenser fins. As the refrig
erant cools in the condenser, it condenses into a liq The refrigerant used in the air conditioner system
uid. Still under high pressure, the liquid refrigerant is Refrigerant-12 (R-12). R-12 is nonexplosive, non
passes into the receiver. The receiver acts as a reser flammable, non-corrosive, has practically no odor and
voir to furnish refrigerant to the expansion (H) valve is heavier than air. Although it is classified as a safe
at all times. From the receiver, the high pressure liq refrigerant, certain precautions must be observed to
uid refrigerant passes to the expansion (H) valve. protect the parts involved and the person who is
The expansion (H) valve meters refrigerant into the working on the unit. Liquid R-12, at normal atmo
evaporator where a low pressure is maintained by sphere pressures and temperatures, evaporates so
the suction side of the compressor. As it enters the quickly that it has the tendency to freeze anything it
evaporator, the refrigerant immediately begins to contacts.
boil by absorbing heat from the air passing over the
evaporator core. Having given up its heat to boil the WARNING: T O AVOID A DANGEROUS EXPLOSION,
refrigerant, the air is cooled and passes into the pas N E V E R W E L D OR S T E A M C L E A N N E A R A I R CON
senger compartment of the vehicle. From the evapo
rator the vaporized refrigerant is drawn back to the
compressor to repeat the cycle.
REFRIGERANT
DITIONING LINES OR COMPONENTS. DO NOT
H E A T R-12 A B O V E 52°C (125°F).
The R-12 in the system is always under pressure.

Because the system is tightly sealed, heat applied to
I
any part could cause this pressure to build up exces
SAFETY PRECAUTIONS sively.
WARNING: E X T R E M E CARE M U S T B E T A K E N T O WARNING: LARGE AMOUNTS OF REFRIGERANT

P R E V E N T ANY LIQUID R E F R I G E R A N T FROM COMING R E L E A S E D IN A CLOSED WORK AREA W I L L DIS
IN CONTACT W I T H T H E SKIN AND E S P E C I A L L Y T H E PLACE T H E OXYGEN AND C A U S E S U F F O C A T I O N .
E Y E S . ALWAYS W E A R S A F E T Y GOGGLES WHEN ALWAYS MAINTAIN GOOD VENTILATION S U R
SERVICING ANY P A R T OF T H E R E F R I G E R A N T S Y S ROUNDING THE WORK AREA.
24 - 2 HEATING AND AIR CONDITIONING J
R-12 gas, under normal conditions, is non-poisonous. Refrigerant oil will absorb moisture from the atmo
sphere if left uncapped. Do not open an oil container
WARNING: THE DISCHARGE OF R-12 GAS NEAR AN until ready to use and install the cap immediately af
OPEN FLAME CAN PRODUCE A VERY POISONOUS ter using. Store the oil only in a clean moisture-free
GAS CALLED PHOSGENE. PHOSGENE IS GENER container.
ATED WHEN A FLAME-TYPE LEAK DETECTOR IS Before connecting an open fitting always install a
USED.
new seal ring. Coat the fitting and seal with clean
refrigerant oil before connecting.
CAUTION: When charging an A/C system always When installing a refrigerant line avoid sharp
keep the tank in an upright position. If the tank i s bends. Position the line away from the exhaust or
on i t s side or upside down, liquid refrigerant will any sharp edges which may chafe the line.
enter the system and may damage the compressor. Tighten fittings only to the specified torque. The
copper and aluminum fittings used in the A/C system
In most instances when charging or adding refrig will not tolerate over tightening.
erant, moderate heat is required to bring the pres When disconnecting a fitting use a wrench on both
sure of the refrigerant above the pressure of the halves of the fitting to prevent twisting of the refrig
system. A bucket or large pan of hot water, not over erant lines or tubes.
52°C (125°F), is all the heat required for this pur Do not open a refrigerant system or uncap a re
pose. Do not heat the refrigerant container with a placement component unless it is as close as possible
blow torch or any other means that would raise the to room temperature. This will prevent condensation
temperature and pressure above this temperature. from forming inside of a component which is cooler
than the surrounding air.
CAUTION: Do not allow liquid refrigerant to touch
Keep service tools and the work area clean. Con
bright metal. Refrigerant will tarnish bright metal
and chrome surfaces. Refrigerant in combination
tamination of A/C system through careless work hab
with moisture i s very corrosive and can cause ex
its must be avoided.
tensive damage to all metal surfaces.
P R E S S U R E GAUGE AND M A N I F O L D A S S E M B L Y
Avoid splashing the refrigerant on any surface. Pressure Gauge and Manifold Assembly Tool
C-3740-A (Fig. 1) is the most important tool used to
RECYCLING service the air conditioning system. The gauge as
(R-12) refrigerant is a chloroflorocarbon (CFC) that sembly is used to determine:
can contribute to the depletion of the ozone layer in • System high side gauge pressures
the upper atmosphere. Ozone filters out harmful ra • System low side gauge pressures
diation from the sun. To assist in protecting the • The correct refrigerant charge
ozone layer, Chrysler Corporation recommends that • System diagnosis
an (R-12) refrigerant recycling device that meets It is designed to provide simultaneous high and low
SAE standard J1991 be used. Contact an automotive side pressure indications, because these pressures
service equipment supplier for refrigerant recycling must be compared to determine the correct system
equipment that is available in your area. Refer to operation.
the operating instructions provided with the recy
cling equipment for proper operation. LOW SIDE GAUGE
The low side gauge is a compound gauge, which
SERVICE PRECAUTIONS means that it will register both pressure and vacuum
Never open or loosen a connection before discharg (Fig. 1). The compound gauge is calibrated 0-1034
ing the system refrigerant. kPa (0-150 psi) pressure and 0-760 mm (0-30 in.) of
When loosening a connection, if any residual pres
mercury vacuum. It is connected to the suction ser
sure is evident, allow it to leak off before opening the
vice valve to check the low side pressure or vacuum.
fitting.
A system which has been opened to replace a com HIGH SIDE GAUGE
ponent or one which has discharged through leakage
The high side gauge is used to check the pressure
must be evacuated before charging.
in the discharge side of the air conditioning system
Immediately after disconnecting a component from
the system, seal the open fittings with a cap or plug. (Fig. 1).
Before disconnecting a component from the system,
clean the outside of the fittings thoroughly.
Do not remove the sealing caps from a replacement
component until ready to install.
J HEATING AND AIR CONDITIONING 24 - 3
MAMiFOLD Purge any air from the high side test hose by open
The gauges are connected into the air conditioning ing the high side hand valve on the manifold for 3 to
systems through a manifold. The manifold has 3 con 5 seconds. The center connection on the manifold
nections (Fig. 1). The low side hose and fitting is con must be open.
nected directly below the low side gauge. The high Purge any air from the low side test hose by open
side hose and fitting is connected below the high side ing the low side hand valve on the manifold for 3 to
gauge. 5 seconds. The center connection on the manifold
The center connection of the manifold is used for must be open.
charging, discharging, evacuating and any other nec The air conditioning system may be operated with
essary service (Fig. 1). Both the high and low sides of the gauge manifold assembly connected in this man
the manifold have hand shutoff valves. The hand ner. The gauges will indicate respective operative
shutoff valves open or close the respective gauge con pressures.
nections to the center service connection or to each
other (Fig. 1). The manifold is constructed so that SERVICE VALVES
pressure will be indicated on the gauges regardless of
DESCRIPTION
the hand valve position.
The discharge (high pressure) and inlet (suction)
COMPOUND GAUGE HIGH SIDE service valves are used for diagnosis, charging, dis
charging and evacuating the system. They are also
used to isolate the system during component Re
moval and Installation.
The service valves are three-position valves (Fig.
2). Normal operating position for the valve stem is
the back-seated (full-out) position. The stem is
turned counterclockwise to place it in this position.
Fig. 1 Pressure Gauge and Manifold Assembly Tool

G-3740-A
CONNECTING THE PRESSURE GAUGE AND
MANIFOLD ASSEMBLY
Remove the protective caps from the service valve
gauge ports and valve stems.
Close both of the hand valves on the gauge mani
fold set.
Connect the compound gauge hose to the compres
sor suction service valve gauge port (low-side).
Connect the high pressure gauge hose to the dis
charge service valve gauge port (high-side).
If necessary, to facilitate installation of the gauge
set, loosen the service valve-to-compressor fitting and
rotate the service valve slightly. Do not allow the
hose to contact the engine or body components.
Tighten the service valve-to-compressor fitting to 34
N»m (25 ft. lbs.) torque. Tighten the flange-type ser 3. T O COMPRESSOR J8924-60
vice valve screws to 20 N»m (15 ft. lbs.) torque.
Set both the service valve stems to the mid-position Fig. 2 Service Valve
or the cracked-position. The gauges will indicate The front seated (full-in) position is used to isolate
high and low side pressure respectively. the compressor from the system. The stem is turned
clockwise to place it in this position.
In the mid-position the gauge port is open. This po low side. For each 300 meters (1000 ft) increase in
sition is used for pressure testing and for charging, altitude, the vacuum must be corrected by 3.37 kPa
discharging and evacuating the system. (1 in. Hg) to compensate for the change in atmo
spheric pressure.
DISCHARGE SERVICE VALVE ADAPTERS FOR E X A M P L E : - A t an of altitude of 300 meters
On occasion, a service hose may not fit a service (1000 ft), a vacuum of 96 kPa (28.5 in. Hg) will be
valve fitting. Adapters are available and can be used equivalent to 99 kPa (29.5 in. Hg) at sea level. When
to achieve service valve connection (Fig. 3), this vacuum level is attained, a minimum evacuation
time of 30 minutes should be allowed to ensure total
RIGHT moisture removal.
MANUFACTURER STRAIGHT FLEX
ANGLE
VACUUM PUMP
7763 7754 The Vacuum Pump Tool C-4069-B and motor
M i l l e r Tools —
must be kept upright at all times to prevent oil
spills.
C-4803 C-4843 — (1) Connect the Pressure Gauge and Manifold As
Draf Tools AC 354 AC 355 sembly Tool C-3740-A to the service valves.
—
(2) Discharge the system.
J9324-94 (3) Connect the center service hose on the gauge
and manifold to the vacuum pump inlet fitting.
Fig. 3 Discharge Service Valve Adapters
(4) Turn both manifold hand valves to the wide
SYSTEM DISCHARGE open position.
The refrigerant must be discharged before replac (5) Start the vacuum pump and observe the vac
ing any system component except the compressor. uum gauge reading.
The compressor can be isolated with the service (6) Test the system for leaks as follows:
valves. • Close the manifold hand valves.
(1) Connect the Pressure Gauge and Manifold As • Stop the vacuum pump and observe the vacuum
sembly Tool C-3740-A to the service valves.
reading.
(2) Open both manifold hand valves fully.
• If the system is leak-free, vacuum will hold steady
CAUTION: Do not allow the refrigerant to discharge at the level indicated when the pump was stopped. If
rapidly. T h e oil in the compressor and system will vacuum remains steady for 3-5 minutes, resume and
be forced out along with the refrigerant. continue evacuation for a minimum of 30 minutes.
• If the system has a leak, vacuum will fall off or
(3) Open both of the service valves slightly (from rapidly drop to a 0 reading. If a leak exists, partially
back-seated to mid-position) and allow the refriger charge the system. Find and repair the leak and re
ant to discharge slowly. sume evacuation.
(7) Continue operating the pump for a minimum of
SYSTEM EVACUATION 30 minutes after attaining lowest vacuum indicated
The system must be evacuated whenever refriger on the gauge.
ant has been discharged or when system refrigerant (8) Close the manifold hand valves and stop the
level has become abnormally low. A vacuum pump is vacuum pump.
used for the evacuation process. (9) Disconnect the center service hose from the
The system must be evacuated to remove any mois vacuum pump. The system is now ready for charging.
ture or air that may have collected in the system. If
moisture is not removed from the system, it will com PORTABLE SERVICE STATION
bine with R-12 to form a highly corrosive substance. The air conditioner service station is a self con
The vacuum pump decreases system pressure by tained, portable unit. It is equipped with a vacuum
creating a vacuum within the system. The pressure pump, metering-charging cylinder, refrigerant sup
drop causes the boiling point of moisture in the sys ply, pressure and vacuum gauges, service hoses and
tem to decrease also. The moisture then boils into a control valves (Fig. 4).
vapor which is easily drawn off by the vacuum. (1) Turn the station vacuum pump control switch
At an ambient temperature of 24°C (75°F) and a OFF (the switch is at the front of the station). The
vacuum of 99 kPa (29.5 in. Hg), water will boil at ap pump control switch must be OFF before connecting
proximately 12°C (54°F). This will produce complete the station to an electrical power source.
vaporization of all moisture in the system. (2) Close all the hand valves.
At elevations above sea level, it may not be possi (3) Connect the red charging hose to the discharge
ble to obtain a vacuum of 99 kPa (29.5 in. Hg) on the service valve.
J HEATING AND A I R CONDITIONING 24 - 5
(12) Close the vacuum control valve and stop the

vacuum pump.
(13) Observe low pressure gauge to determine if a
system leak exists. If the system is leak-free, the sys
tem is now ready for charging.
SYSTEM CHARGE
CHARGE CAPACITY
The recommended system charge is 1.1 kg (38 oz.)
of R-12 refrigerant for XJ vehicles and 0.9 kg (32 oz.)
for YJ vehicles.
Add an additional 28 grams (1 oz.) of compres
sor oil to the system when a hose, receiver-drier,
condenser, expansion valve or evaporator core
is replaced.
MUL TI*REFRIGERANT DISPENSER

The following charging procedure is based on the
use of Pressure Gauge and Manifold Tool C-3740-A
and Multi-Refrigerant Dispenser Tool C-4242.
Fig. 4 Portable Service Station WARNING: W E A R G O G G L E S T O P R O T E C T T H E

EYES.
(4) Connect the blue charging hose to the inlet
(suction) service valve. (1) Connect pressure gauge and manifold.
(5) Discharge the system. Leave the suction and (2) Mid-position the service valves.
discharge service valves in the mid-position. (3) Evacuate the system.
(4) Close both manifold hand valves.
CAUTION: T h e system must be completely dis
(5) Disconnect the service hose from the vacuum
charged before evacuating. If the system i s still
pump and connect it to the center fitting of multi-re
charged, refrigerant can enter and damage the vac
frigerant dispenser.
uum pump.
(6) Close all of the petcock valves on the dispenser.
(6) Connect the vacuum pump hose to the vacuum (7) Attach the necessary number of refrigerant
pump inlet. cans to the dispenser. Refer to Charge Capacity for
(7) Open the low and high pressure control valves the amount of R-12 required to charge the system.
on the charging station. The refrigerant containers may be placed upright in
(8) Start the vacuum pump. Open the vacuum con warm water (at a maximum temperature of 52°C
trol valve and note the vacuum reading. (125°F) to cut down charging time.
(9) Test the system for leaks as follows: (8) Bleed air from the manifold and dispenser.
• Close the manifold hand valves. Loosen the center service hose at the manifold. Open
• Stop the vacuum pump and observe the vacuum a dispenser petcock and allow refrigerant to purge
reading. air from the components. Tighten the service hose
• If the system is leak-free, vacuum will hold steady and close the petcock after all air is purged.
at the level indicated when the pump was stopped. If (9) Open the low pressure (suction) gauge hand
vacuum remains steady for 3-5 minutes, resume and valve and a petcock valve. Do not open the discharge
continue evacuation for a minimum of 30 minutes. (high pressure) gauge hand valve at this time.
• If the system has a leak, vacuum will fall off or
WARNING: U S E E X T R E M E CAUTION W H E N T H E
rapidly drop to a 0 reading. If a leak exists, partially
ENGINE I S O P E R A T I N G . DO NOT S T A N D IN A DI
charge the system. Find and repair the leak and re
R E C T L I N E W I T H T H E FAN. DO N O T P U T Y O U R
sume evacuation.
H A N D S N E A R T H E P U L L E Y S , B E L T S O R F A N . DO
(10) Continue evacuating the system for a mini
NOT W E A R L O O S E CLOTHING.
mum of 30 minutes after attaining the lowest vac
uum level. (10) Start the engine. Set the air conditioner con
(11) Fill the station charging cylinder while the trols at maximum cooling. Compressor operation will
system is evacuating. charge the inlet (suction) side of the system.
24 - e HEATING AND AIR CONDITIONING J
(11) When the first refrigerant can is empty, open (13) Close the refrigerant control valve and the
another petcock valve to continue charging the sys high pressure valve on the charging station.
tem.
(12) Continue adding R-12 until the system is fully CAUTION: Do not permit the liquid level to drop be
charged. The frost line on the refrigerant container low 0 on the cylinder sight glass.
will indicate how much refrigerant has entered the
system. If an accurate scale is available, weigh the (14) Close the manifold gauges after completion of
refrigerant cans during the charging procedure to the charging operation and check the high and low
verify the amount of refrigerant added. side pressures.
(13) When the system is fully charged, close the (15) Check system operation.
manifold low pressure gauge hand valve and all the CAUTION: Do not check system pressures until the
dispenser petcock valves. high and low pressure valves on the charging sta
(14) Start the engine. Operate the A/C system 5 to tion are closed. T h e low pressure gauge could be
10 minutes so it will stabilize. damaged if the valves are open.
(15) Check system operation.
(16) Close all the valves on the charging station
PORTABLE SERVICE STATION and close the refrigerant drum valve when all the op
(1) Fill the station charging cylinder. Refrigerant erations are completed.
should be observed rising in the cylinder sight glass. (17) Back-seat the service valves by turning them
(2) Slightly open the valve at the top of the cylin fully counterclockwise. Install the quick seal caps on
der when pressure in the charging cylinder and re the valves afterward.
frigerant supply tank are equal. This relieves head (18) Disconnect the charging hoses from the ser
pressure allowing refrigerant to continue filling the vice valves. A small amount of refrigerant remaining
cylinder. in the hoses will escape.
(3) Observe the pressure gauge at the top of the (19) Discharge any R-12 left in the charging cylin
cylinder. Rotate the plastic cover on the cylinder un der. The cylinder is not designed to store refrigerant.
til the pressure heading column corresponds with the
gauge pressure in-line with the sight glass. COMPRESSOR OIL LEVEL
F O R E X A M P L E : — T h e pressure gauge at the top The compressor oil level must be checked and ad
of the cylinder indicates 483 kPa (70 psi). Locate the justed if the system has been discharged rapidly, or
column with the pressure heading of 483 (70) and ro when a component has been replaced. If a replace
tate the cover so the 483 (70) column aligns with the ment compressor is being installed, it must be filled
sight glass. with new compressor oil (Suniso 5GS, or equivalent).
(4) When refrigerant reaches the correct level in The normal quantity of oil required for the com
the sight glass, close the right hand valve at cylinder pressor and entire system is 136 ml (4.6 oz.) for SD
base and on the refrigerant drum. 709 compressor. DO NOT overfill the compressor. Ex
(5) Close the valve at the top of the charging cyl cessive amounts of oil in the system will hinder com
inder. pressor operation and reduce cooling efficiency.
(6) Check for bubbles in the refrigerant using the
cylinder sight glass. If bubbles appear in the refrig CAUTION: T h e compressor i s a high speed unit.
erant, tilt the charging station rearward momen Satisfactory operation i s dependent on sufficient lu
tarily. brication; however, excess oil will hinder cooling ef
(7) Connect the heating element cord to the power ficiency.
pack receptacle and turn the heater switch ON.
(8) Allow the refrigerant to warm for about 10 Two oil level checking procedures are necessary.
minutes while the vacuum pump is operating. Use Procedure (A) when the compressor is being re
placed and the system was discharged properly (no
WARNING: W E A R G O G G L E S TO P R O T E C T T H E
oil loss). Use Procedure (B) for routine maintenance
EYES.
or when checking oil level after replacing a system
(9) Discharge and evacuate the system. component.
(10) Close the low pressure valve on the charging In cases where rapid loss of refrigerant and oil
station. occurred, the system must be evacuated and
(11) Fully open the left hand refrigerant control purged. Then the compressor must be filled with
valve at the base of the cylinder and the high pres the necessary amount of oil to fill the entire sys
sure valve on the charging station. tem.
(12) Charge the system.
PROCEDURE A
M O U N T I N G ANGLE
(1) Remove the oil filler plug, discharge cap and RIGHT
suction port caps from the original and replacement (AS FACING
compressor. CLUTCH)
(2) Use a clean container to drain the oil from the
replacement compressor. Drain the oil through the
oil filler plug hole, the discharge and suction. Then
rotate clutch front plate several times to push the oil
on cylinder out to discharge chamber of cylinder VIEW W H E N
head and drain the oil from discharge port. COMPRESSOR ANGLE
(3) Drain the oil from the original compressor into RIGHT
a measuring cup or graduated beaker in the same
way as Step 2. Note the amount of oil drained.
(4) Fill the replacement compressor with the same
amount of oil drained from the original compressor
plus 1 additional fluid ounce.
FOR EXAMPLE:—If the old compressor contained
103.5 ml (3.5 oz.) of oil, fill the replacement compres
sor with a total of 133 ml (4.5 oz.) of oil.
PROCEDUREB ES924-208
(1) Start the engine and operate the engine at idle.
(2) Operate the air conditioning system for 10 min Fig. 5 Check Oil Level
utes to return the maximum amount of oil in the sys
tem to the compressor. MOUNTING ACCEPTABLE MOUNTING ACCEPTABLE
(3) Stop the engine and disconnect the magnetic ANGLE OIL LEVEL ANGLE OIL LEVEL
clutch feed wire. (DEGREE) INCREMENTS (DEGREE) INCREMENTS
(4) Front-seat the discharge and suction service
0 3-5 40 7-9
valves.
(5) Determine the mounting angle. 10 4-6 50 8-10
(a) Position an Angle Gauge across the flat sur
20 5-7 60 9-11
faces of the front mounting ears.
(b) Center the bubble. 30 6-8 90 10-12
(c) Read the mounting angle to the closest de J9124-23
gree.
(d) These vehicles should have 0° mounting an Fig. 6 Mounting Angle/Oil Level Table
gle. (10) If the increments read on the dipstick do not
(6) Remove the oil filler plug. Position internal match the table, add or subtract oil to the mid-range
parts by rotation of front plate counterweight to 30° value.
angle (Fig. 5).
FOR EXAMPLE:—If the mounting angle is 10°
(7) Insert the dipstick tool to its STOP position.
and the dipstick increment is 3, add oil in 30 ml (1
The Dipstick Tool is part of Tool Kit 7851. The stop
is the angle near the top of the dipstick. The bottom fluid oz.) increments until 5 is read on dipstick.
surface of the angle must be flush with the surface of (11) Check that the sealing O-ring is not twisted.
the oil filler hole. (12) Seat and O-ring must be clean.
(8) Remove dipstick. Count increments of oil. (13) Install the compressor oil filler plug. Tighten
(9) Use mounting angle table to determine correct the plug to 10 N®m (7 ft. lbs.) torque. Do not over
oil level for the compressor (Fig. 6). tighten the plug to stop a leak.
24 - 8 H E A T I N G A N D A I R CONDITIONING
J
SERVICE DIAGNOSIS—MECHANICAL
GENERAL (7) Observe the high and low side pressures. The
The reason for a decrease in cooling or heating ef evaporator suction pressure should be 207-241 kPag
ficiency must be understood before attempting repair (30-35 psig). The compressor discharge pressure
or replacement of parts. Determined if the condition should be 1103-1633 kPag (160-235 psig). It should
is the air conditioner, the heating system, its compo be noted that high ambient temperature and humid
nents or the in the air flow system. ity conditions will cause higher pressures and tem
The air conditioning system generally operates at perature conditions. If the clutch cycles, take
peak efficiency at normal highway speeds. However, readings before clutch disengages.
a slight reduction in cooling efficiency may be expe (8) If pressures are abnormal, refer to the Pressure
rienced in congested city driving conditions; espe and Performance Diagnosis Charts.
cially when ambient temperatures are high. The following charts have been developed for quick
When diagnosing a gradual decrease in cooling ef reference. If the step by step method used is not com
ficiency, remember to check condition of the .con pletely understood, refer to the correct section of the
denser and radiator fins. Air flow blockage of either Service Manual for more detailed information.
component, caused by dirt, foreign material or in
sects, will affect the air conditioning and engine cool COMPRESSOR SHAFT T E S T
ing systems. Vehicles equipped with a protective (1) Isolate and purge compressor.
screen, can restrict air flow to the radiator and con (2) Front-seat the ' service valves and remove
denser. valves from the compressor.
During high outside operating temperatures, a (3) Disengage the clutch.
slight increase in engine coolant temperature will oc (4) Rotate the compressor shaft using a socket and
cur when the air conditioner is operating. wrench on the shaft nut. If severe rough spots or
"catches" are felt while rotating the compressor
A/C PERFORMANCE TEST shaft be sure to replace the compressor.
The pressure developed on the high side and low
side of the compressor indicates whether the system A/C LEAK TESTS
is operating properly. COMPRESSOR VALVE PLATE
WARNING: USE E X T R E M E CAUTION WHEN THE This test can be preformed with the compressor in
ENGINE I S O P E R A T I N G . DO N O T S T A N D IN A DI stalled in the vehicle.
R E C T L I N E W I T H T H E F A N . DO N O T P U T Y O U R Discharge or Suction Valve Breakage—When
H A N D S N E A R T H E P U L L E Y S , B E L T S O R FAN. DO compressor is operating at idle speed, compressor
NOT W E A R L O O S E CLOTHING. makes a "clacking" sound. Preform the Pressure Bal
ancing Test.
Head Gasket Breakage—At idle speed, discharge
WARNING: W E A R S A F E T Y G O G G L E S W H E N S E R pressure does not increase to normal condition and
VICING THE REFRIGERATION SYSTEM suction pressure is high. Preform the Pressure Bal
ancing Test.
(1) Attach an engine tachometer and refrigerant Pressure Balancing Test:
Pressure Gauge and Manifold Assembly Tool (1) Connect manifold gauge set to suction and dis
C-4740-A. charge ports.
(2) Close both hand valves on the gauge and man (2) Run compressor for 5 minutes at idle speed and
ifold assembly. stop.
(3) Set both service hand valve stems to the mid- (3) Measure elapsed time that discharge pressure
position. is balanced to suction pressure. If less than 2 min
(4) Operate air conditioning system with the en utes, it is determined that discharge valve or head
gine running at 1,000 RPM. Set the controls for max gasket is broken.
imum A/C, temperature control on full cool and
blower switch on high. REFRIGERANT LEAK TEST
(5) Engine should be warmed up with doors, win External leaks in the system can be located using
dows and hood closed. an electronic detector.
(6) Insert a thermometer into center discharge air The electronic leak detector is recommended be
outlet and observe the air temperature. The temper cause it is light, accurate and most important, does
ature should be approximately 7°C (45°F) at 27°C not expose the user to toxic gas fumes. An electronic
(80°F) ambient temperature after 5 minutes of oper leak detector will locate R-12 leaks as small as 0.3
ation. ounce per year.
J HEATING A N D A I R CONDITIONING 24 - 9
PRESSURE DIAGNOSIS
CONDITION 1 CORRECTION
POSSIBLE CAUSE
L O W SIDE L O W — (1) System refrigerant Is low. (1) Evacuate, leak test and charge the system.
HIGH SIDE L O W
(2) Expansion valve is restricted. (2) Replace the expansion valve.
L O W SIDE H I G H — (1) Internal leak in the compressor - w o r n . (1) Remove the compressor cylinder head and
H I G H SIDE L O W inspect the compressor. Replace the valve
plate assembly if necessary. If the com
pressor pistons, rings o r cylinders are
excessively w o r n o r scored, replace the
compressor.
(2) Cylinder head gasket is leaking. (2) Install a replacement cylinder head gasket.
(3) Drive belt slipping. (3) Adjust the belt tension.
L O W SIDE H I G H — (1) Condenser fins obstructed. (1) Clean the condenser f i n s .

H I G H SIDE H I G H
(2) A i r In the system. (2) Evacuate, leak test and charge the system.
(3) Expansion valve is defective. (3) Replace the expansion valve.
(4) Loose or w o r n fan belts. (4) Adjust or replace the belts as necessary.
(5) Refrigerant overcharge. (5) Bleed off refrigerant.
L O W SIDE L O W — (1) Expansion valve is defective. (1) Replace the expansion valve.
H I G H SIDE H I G H
(2) Restriction in the refrigerant hose. (2) Check the hose f o r kinks—replace if
necessary.
(3) Restriction in the receiver/drier. (3) Replace the receiver/drier.
(4) Restriction in the condenser. (4) Replace the condenser.
L O W SIDE A N D H I G H (1) A i r in the system. (1) Evacuate, leak test and charge the system.
SIDE N O R M A L
( I N A D E Q U A T E COOLING) (2) Excessive oil in system. (2) Discharge and drain oil. Restore proper
oil level, evacuate, leak test and charge
system.
J9124-44
24 - 1 0 HEATING A N D A I R CONDITIONING
J
PERFORMANCE DIAGNOSIS
COMPRESSOR NOISE (1) Broken valves. (1) Replace the valve plate.
(2) Discharge, evacuate and install the correct

(2) Overcharged.
charge.
(3) Isolate the compressor and check the oil

(3) Incorrect oil level.
level. Correct as necessary.
(4) Replace the compressor.

(4) Piston slap.
(5) Broken rings. (5) Replace the compressor.
(6) Drive belt pulley bolts are loose. (6) Tighten w i t h the correct torque specification.
EXCESSIVE VIBRATION (1) Incorrect belt tension. (1) Adjust the belt tension.
(2) Clutch loose. (2) Tighten the clutch.
(3) Overcharged. (3) Discharge, evacuate and install the correct

charge.
(4) Pulley is misaligned. (4) Align the pulley.
CONDENSATION (1) Drain hose plugged or improperly (1) Clean the drain hose and check f o r proper
D R I P P I N G IN T H E positioned. installation.
PASSENGER
COMPARTMENT (2) Insulation removed or improperly installed. (2) Replace the insulation on the expansion
valve and hoses.
F R O Z E N EVAPORATOR (1) Faulty thermostat or thermistor probe. (1) Replace the thermostat or thermistor probe.
COIL
(2) Thermostat capillary tube or thermistor (2) Install the capillary tube or thermistor
improperly installed. correctly.
(3) Thermostat not adjusted properly. (3) Adjust the thermostat.
J9124-48
HEATING AND AIR CONDITIONING 24 - 11
J
WARNING: T H E H A L I D E T O R C H R E Q U I R E S AN time, until the light illuminates-then goes out when
O P E N F L A M E F O R L E A K D E T E C T I O N . W H E N R-12 the tip is removed from the leak port.
I S E X P O S E D TO AN O P E N F L A M E , IT T U R N S INTO (5) Begin leak testing. Move the flexible probe
P H O S G E N E GAS WHICH IS POISONOUS. slowly under all suspect connections, joints and seals.
Because R-12 refrigerant is heavier than air, leaks
(1) Calibrate the detector as outlined in the manu
facturer's instructions. are more readily detected on the lower side of com
(2) Remove the flexible detector probe from the ponents being checked. The leak indicator light will
case. illuminate when a leak is detected. The indicator
(3) Turn the detector control switch ON. light will go out if the probe tip is held near the leak
(4) Prepare the detector for use. point for an extended period.
• Place the flexible probe tip near the leak port on (6) Repair leaks as required.
the detector. (7) Evacuate and charge the system after leaks are
• Adjust the BAT thumb-wheel a few teeth at a corrected.
HEATING SYSTEM DIAGNOSIS
BLOWER M O T O R (1) B l o w n fuse. (1) Replace fuse.

WILL N O T T U R N
A T A N Y SPEED (2) Loose connection. (2) Inspect and tighten.
(3) Defective ground. (3) Clean and tighten.
(4) Faulty switch. (4) Replace switch.
(5) Faulty motor. (5) Replace motor.
(6) Faulty resistor. (6) Replace resistor.
BLOWER M O T O R T U R N S (1) Faulty switch. (1) Replace switch.

A T O N E SPEED O N L Y
(2) Faulty resistor. (2) Replace resistor.
BLOWER M O T O R T U R N S (1) Intake blocked. (1) Clean intake.

B U T DOES N O T
CIRCULATE AIR (2) Fan not secured to the motor shaft.. (2) Tighten securely.
(3) Outside air mode door inoperative. (3) a. Check and replace outside air door
vacuum motor, if necessary.
b. Check and repair vacuum controls,
as required.
HEATER WILL NOT HEAT (1) Coolant does not reach proper (1) Check and replace thermostat if
temperature. necessary.
(2) Heater core blocked internally. (2) Flush o r replace core if necessary.
(3) Heater core air-bound. (3) Purge air f r o m core.
(4) Blend-air door not in proper position. (4) Adjust cable.
HEATER WILL NOT DEFROST (1) Control cable adjustment incorrect o r (1) Adjust control cable o r replace
vacuum motor inoperative. vacuum motor.
(2) Defroster hose damaged o r duct seal (2) Replace defroster hose or correct
leakage. duct seal.
J9124-49
AIR CONDITIONING SYSTEM DIAGNOSIS
INSUFFICIENT O R N O
COOLED A I R
NO
CHECK T H E A I R T E S T T H E DRIVE REPLACE APPLY 12V DIRECTLY T O

DISTRIBUTION DOORS; BELT T E N S I O N THE FUSE T H E BLOWER M O T O R
ENSURE T H A T THERE
ARE N O
OBSTRUCTIONS IN T H E
VENT CHANNELS
REPLACE T H E
BLOWER MOTOR
YES
REPAIR T H E
WIRE HARNESS
REPLACE T H E
CLUTCH
CHARGE T H E
SYSTEM
REPLACE T H E
PRESSURE SWITCH
REPLACE
THERMOSTAT
REPLACE T H E
E X P A N S I O N VALVE
COMPRESSOR DIAGNOSIS
Spt§pte« Problem Dksgnosgg* mm§ Infection €mmm and Remedy

STEP
SEQUENCE REPLACE O R REPAIR:
o U N U S U A L L Y HIGH S U C T O N
1
z
PRESSURE W I T H U N U S U A L L Y
L O W DISCHARGE PRESSURE IF REMOVE VALVE PLATE AND INSPECT
B R O K E N H E A D OR BLOCK GASKET
BROKEN O R DEFORMED
OR VALVE PLATE-TEST. REED VALVE
DO FOREIGN SUBSTANCE U N D E R
REED VALVE O R GASKET
. UJ CHECK F O R L O W
REFRIGERANT CHARGE.
a.
UNUSUALLY L O W REPLACE O R REPAIR:
S U C T I O N A N D DISCHARGE
PRESSURE LEAK-CHECK COMPRESSOR. SHAFT SEAL LEAK
SERVICE P O R T
CYLINDER HEAD LEAK
8 LEAK-CHECK A N D DIAGNOSE SYSTEM.
GASKET LEAK
OIL FILLER PLUG LEAK
CRACKED CYLINDER BLOCK
o 1 CHECK BELT T E N S I O N .
FRONT HOUSING
O-RING LEAK
INTERMITTENT OR
3 O
INOPERATIVE ADJUST AIR GAP.
m
CHECK CLUTCH AIR GAP.
5s=0
REPLACE O R REPAIR:
CHECK CLUTCH VOLTS, AMPS, B R O K E N LEAD W I R E
COIL LEAD W I R E . CLUTCH COIL D E F E C T - I N T E R N A L
OSS SYSTEM G R O U N D
gSO ROUGH RUNNING PERFORM S H A F T T U R N I N G
2zz SMOOTHNESS TEST.
COMPRESSOR F A I L U R E - I N T E R N A L
Symptom Problem Diagnosis and inspection Cause and Remedy
i CHECK COMPRESSOR
MOUNTING COMPONENTS.
CLUTCH ENGAGED
2 CHECK E N G I N E C O M P O N E N T S .
3 CHECK F O R I N T E R M I T T E N T O R ADJUST AIR G A P -

SLIPPING CLUTCH. DEFECTIVE COIL.
4 CHECK F O R PROPER RECHARGE A N D RECHECK.

REFRIGERANT CHARGE.
m
I c
5 CHECK CLUTCH BEARING. REPLACE BEARING.
Z
<
D 6 CHECK OIL LEVEL. RESTORE T O PROPER LEVEL.
m
3
Z
t
PERFORM S H A F T T U R N I N G COMPRESSOR F A I L U R E - I N T E R N A L !
SMOOTHNESS TEST.
REPLACE O R REPAIR:
8 REMOVE VALVE PLATE A N D INSPECT.
BROKEN DISCHARGE VALVE REED
OR RETAINER
B R O K E N S U C T I O N VALVE REED
B R O K E N GASKET
CLUTCH DISENGAGED,
"CHATTERING" 1 CHECK AIR GAP.
REPLACE O R REPAIR:
ADJUST AIR GAP
DEFECTIVE CLUTCH PULLEY O R
F R O N T PLATE
J8924-74
SERVICE DIAGNOSIS—ELECTRICAL
BLOWER CONTROLS - X J VEHICLES The A/C low pressure switch opens when there is
not enough refrigerant in the system. When this hap
DESCRIPTION pens, voltage is no longer present at the Engine Con
The blower motor delivers air to the inside of the troller. The Engine Controller will turn off the A/C
vehicle. Its speed is controlled by the blower switch clutch relay. With the proper refrigerant level in the
and the blower resistors. With the switch in LO, part system, the low pressure switch remains closed.
of the battery voltage is supplied to the motor When the evaporator temperature is low enough to
through all of the resistors. The motor runs slowly. ice the cooling coils, the thermostat switch opens.
As the blower switch is moved to a higher speed, the The Engine Controller will turn off the A/C clutch.
switch allows more voltage to be applied to the The thermostat switch closes when the temperature
blower motor, which will increase its speed. When rises. The Engine Controller will then turn the A/C
the switch is in HI, the blower resistors are bypassed clutch relay on again.
and battery voltage is applied directly to the blower
motor. The motor runs at the fastest speed in this DIAGNOSIS
mode. Refer to the Group 8W, Wiring Diagrams for com
plete system schematic.
DIAGNOSIS With engine running, Engine Controller may delay
Refer to the Group SW, Wiring Diagrams for com A/C clutch up to 30 seconds.
plete system schematic. 1. A/C COMPRESSOR CLUTCH INOPERA
1. BLOWER MOTOR INOPERATIVE TIVE
• Remove and inspect fuse. If the fuse is blown, re Clutch connector disconnected.
place fuse. • Jumper fused test lead, battery to clutch connec
2. BLOWER MOTOR INOPERATIVE (HI Posi tor, clutch should operate. If not, replace compressor
tion) clutch assembly.
Put the ignition switch in RUN, the select switch 2. A/C LOW PRESSURE SWITCH
in HEAT and the blower switch on HI. Ignition in RUN, A/C controls in MAX or NORM.
• Blower motor connector (Terminal A ) should be • Low pressure switch connector (Terminal A )
battery voltage. If not go to next step. should be battery voltage. If not, repair open to select
• Blower motor connector (Terminal B) should be 0 switch.
ohms. If not, repair wire to ground. • Low pressure switch connector (Terminal C)
• Blower switch connector (Terminal C) should be should be battery voltage. If not, check switch resis
battery voltage. If battery voltage replace blower tance and check freon pressure.
switch. If not, replace select switch. 3. A/C CLUTCH R E L A Y
3. BLOWER MOTOR INOPERATIVE (LO, M l Engine RUNNING, A/C controls in MAX or
& M2 Positions) NORM.
Ignition switch in RUN, select switch in HEAT. • Relay connector Pin 4 to ground should be battery
• Blower resistors connector (Terminal D) should be voltage. If not, check fuse F6 in Power Distribution
battery voltage. If not, replace select switch. Center.
• Blower resistors connector (Terminal C) should be • Ground A/C clutch relay (Terminal 5) should have
battery voltage. If not, replace blower switch. A/C compressor clutch engagement. If not, check En
• Blower resistors connector (Terminal A) should be gine Controller Terminals 27, 28 and 34.
battery voltage. If not, replace blower switch.
• Blower resistors connector (Terminal B) should be HEATING S Y S T E 1 - Y J VEHICLES
battery voltage. If not, replace blower resistor.
DESCRIPTION
AIR CONDITIONING SYSTEM—XJ VEHICLES The blower motor circuit begins at a 25 amp fuse
that receives its battery feed from the ignition
DESCRIPTION switch. From the fuse the circuit extends to a micro-
The A/C Compressor Clutch is belt-driven by the switch mounted on the heater control.
engine. A clutch, operated by a solenoid, automati The micro-switch is normally closed is operated by
cally turns the compressor on and off to control evap a cam on the heater control lever. In all heater con
orator icing. trol lever positions, except OFF and VENT, the
The A/C Compressor Clutch operation is controlled blower motor electrical circuit is complete. In the
by several components: the A/C Low-Pressure OFF and VENT positions the cam depresses the mi
Switch, Thermostat Switch, Fuel Pump Relay, A/C cro-switch lever opening the electrical circuit to the
Clutch Relay and the Engine Controller. blower motor.
J H E A T I N G A N D A I R CONDITIONING 24 - 1 5
The blower switch allows the driver to select 1 of 3 • Blower motor voltage should be battery voltage. If
blower speeds—low, medium and high. In the high not, repair open from blower switch.
speed position, the switch connects the motor directly • Blower motor case to clean chassis ground should
to the battery source. The remaining 2 slower speeds be 0 ohms. If not, repair/replace blower motor.
are accomplished by routing the battery source
through a resistor assembly. AIR CONDITIONING SYSTEM—YJ VEHICLES
The resistor and switch are wired in such a way
that only a single wire is needed to operate the DESCRIPTION
blower motor at 3 different speeds. The air conditioning circuit consists of 3 segments;
battery supply, blower motor and compressor clutch.
DIAGNOSIS The 3 segments have a common connection point at
Refer to Group 8W, Wiring Diagrams for complete the blower switch.
system schematic. The power supply segment of the circuit extends
1. HEAT/OFF MICRO-SWITCH from the 25 amp HTR/FAN fuse to the blower
Place selector lever in heat mode and turn ignition switch. From the blower switch, battery feed is
switch to RUN. routed to the blower motor and compressor clutch
• Heat/Off micro-switch connector supply side should segments of the circuit.
be battery voltage. If not, repair open from fuse #12. The blower motor segment consists of the 3 wires
• Heat/Off micro-switch connector output side should from the blower switch to the motor, the motor itself
be battery voltage. If not, replace Heat/Off micro- and the motor ground wire. Through the switch, the
switch. 3 wires connect the motor brushes to battery supply.
2 . BLOWER SWITCH When connected to battery feed, the separate brushes
Turn ignition switch to RUN and place selector le provide the 3 blower speeds—LO, MED, and HIGH.
ver in HEAT mode. In all blower switch positions except OFF, the com
• Blower switch (terminal A) should be battery volt pressor clutch segment of the circuit also receives
age. If not, repair open from HEAT/OFF switch con battery feed. ON and OFF cycling of the compressor
nector output side to blower switch. and therefore the temperature of the outlet air is
• Blower switch (terminal D) with blower switch in regulated by the thermostatic control. A thermal sen
HI ~hould be battery voltage. If not, replace blower sor extends from the control to the evaporator hous
switch. ing. When the temperature of the evaporator drops
• Blower switch (terminal C) with blower switch in below the set temperature, the thermostatic control
LO should be battery voltage. If not, replace blower opens the clutch circuit. The circuit remains open un
switch. til evaporator temperature rises above the set tem
• Blower switch (terminal B) with blower switch in perature.
MED should be battery voltage. If not replace blower The compressor clutch segment of the circuit also
switch. contains a low pressure switch. If the pressure in the
3. BLOWER RESISTOR refrigerant system drops due to a leak, the circuit is
Turn ignition switch to RUN for voltage tests and opened to prevent damage to the compressor.
turn ignition switch to OFF for resistance tests. The last component in the compressor clutch seg
• Blower resistor (Terminal A) with blower switch in ment of the circuit is the clutch coil. When the coil is
LO should be battery voltage. If not, repair open be connected to battery feed, its windings form an elec
tween blower switch and blower resistor. tromagnet that pulls the clutch hub against the
• Blower resistor (Terminal B) with blower switch in clutch pulley.
MED should be battery voltage. If not, repair open
between blower switch and blower resistor. DIAGNOSIS
• Blower resistor (Terminal C) with blower switch in
BLOWER MOTOR
HI should be battery voltage. If not, repair open be
Refer to Group 8W, Wiring Diagrams for complete
tween blower switch and blower resistor.
system schematic.
• Blower resistor between Terminals A and B should
1. FUSE-Ignition in RUN.
be 0.35 ohms, if not replace blower resistor.
• Heater blower motor operates. If not, check fuse
• Blower resistor between Terminals B and C should
#12.
be 0.85 ohms. If not, replace blower resistor.
• Battery side of fuse #12 should be battery voltage.
• Blower resistor between terminals A and C should
If not, repair open from ignition switch.
be 1.20 ohms, if not replace blower resistor.
• A/C blower switch (terminal A ) should be battery
4. BLOWER MOTOR
voltage. If not, repair open from fuse #12.
Turn blower motor switch to HI and place selector
lever in HEAT mode. Turn ignition switch to RUN
for voltage tests or to OFF for resistance tests.
% BLOWER SWITCH-Ignition In RUN* With engine running, Engine Controller may delay
• A/C blower switch (Terminal A ) with blower A/C clutch up to 30 seconds.
switch in any position should be battery voltage. If 1. COMPRESSOR CLUTCH.
not, repair open from fuse panel. • Jumper wire from battery positive post to A/C
• A/C blower switch (Terminal L) with blower compressor clutch connector (Terminal A ) , clutch
switch in LO should be battery voltage. If not, re should engage. If not, go to next step with jumper in
place switch. stalled.
• A/C blower switch (Terminal M) with blower • Jumper wire from clutch coil frame to chassis
switch in MED should be battery voltage. If not, re ground, clutch should engage. If not, repair clutch
place switch. coil ground or replace coil.
• A/C blower switch (Terminal H) with blower 2. LOW PRESSURE SWITCH
switch in HI should be battery voltage. If not, replace
Turn ignition switch to RUN, A/C blower switch to
switch.
ON and thermostatic control set to MAX cool.
3. BLOWER MOTOR
• A/C low pressure switch connector (Terminal A )
Turn ignition switch to RUN for voltage tests and
turn ignition switch to OFF for resistance tests. should be battery voltage. If not, proceed to thermo
• A/C blower housing to ground (Terminal G) should static control tests (Step 3).
be 0 ohms. If not, repair ground connection. If the • Jumper wire across A/C low pressure switch con
blower motor is still inoperative, replace motor. nector (Terminals A and B), clutch should engage. If
• A/C blower motor connector (Terminal C) with not, check system refrigerant charge. If system is
blower switch in LO should be battery voltage. If not, properly charged, replace A/C low pressure switch.
repair open from blower switch. If the blower motor 3. THERMOSTATIC CONTROL
is still inoperative, replace motor. Turn ignition switch to RUN, A/C blower switch to
• A/C blower motor connector (Terminal B) with ON and thermostatic control set to MAX cool.
blower switch in MED should be battery voltage. If • Thermostatic control connector (Terminal A )
not, repair open from blower switch. If the blower should be battery voltage. If not, repair open from
motor is still inoperative, replace motor. blower switch.
• A/C blower motor connector (Terminal A ) with • Thermostatic control connector (Terminal B)
blower switch in HI should be battery voltage. If not, should be battery voltage. If not, replace thermo
repair open from blower switch. If the blower motor static control.
is still inoperative, replace motor. • A/C low pressure switch connector (Terminal A)
should be battery voltage. If not, repair open from
COMPRESSOR CLUTCH thermostatic control.
Refer to Group 8W, Wiring Diagrams for complete
system schematic.
H E A T I N G A N D A I R CONDITIONING 24 - 1 7
J
COMPRESSOR OVERHAUL
INDEX
page page
Compressor 17 Description 17
Compressor Isolation 17 Magnetic Clutch 18
Compressor Shaft Seal 21 Purging Compressor of Air 17
Cylinder Head/Valve Plate 23
DESCRIPTION PURGING COMPRESSOR OF AIR

The A/C system uses a Sanden compressor. This The compressor must be purged of air whenever it has
compressor is a 7 piston design. Designated the SD- been isolated for an oil level check or other service pro
709, the compressor is mounted on the front right cedures without discharging the entire system.
side of the engine and is driven by a serpentine belt. (1) Cap the service gauge ports on both of the ser
System lubrication is provided by 135cc ±15cc (4.6 vice valves.
cu. in. ±0.5 cu. in.) of 500 viscosity refrigerant oil. (2) Back-seat the suction service valve to allow the
The clutch used on the compressor consists of 3 ba system refrigerant to enter the compressor.
sic components: the pulley, front plate and the field (3) Place the discharge service valve in the mid-po
coil. The pulley and field coil are attached to the sition or cracked-position.
front head of the compressor with tapered snap rings. (4) Loosen the discharge service valve gauge port
The hub is keyed to the compressor shaft and is re cap to permit the refrigerant to force any air out of
tained on the shaft with a self-locking nut. Special the compressor.
service tools are required to remove and install the (5) Back-seat the discharge service valve and
clutch plate on the compressor shaft. tighten the gauge port cap.
(6) The compressor is now ready for service.
COMPRESSOR ISOLATION
It is not necessary to discharge the system for com COMPRESSOR
pressor removal. The compressor can be isolated from REMOVAL
the remainder of the system and eliminate the need (1) Isolate the compressor.
for recharging when performing compressor service. (2) Disconnect negative cable from battery.
(1) Connect pressure gauge and manifold. (3) Disconnect the clutch lead wire.
(2) Close both gauge hand valves. (4) Remove the discharge and inlet (suction) ser
(3) Mid-position both service valves. vice valves from the compressor. Plug or tape all the
openings.
WARNING: USE EXTREME CAUTION WHEN THE (5) Remove the serpentine drive belt (refer to
ENGINE IS OPERATING. DO NOT STAND IN A DI Group 7, Cooling System for the proper procedure).
RECT LINE WITH THE FAN. DO NOT PUT YOUR (6) Remove the bolts and lift the compressor from
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO the mounting bracket (Fig. 1).
NOT WEAR LOOSE CLOTHING.
INSTALLATION
(4) Start the engine and operate the air condition If a replacement compressor is being installed;
ing system. check the oil level. Add or subtract oil as neces
(5) Turn the suction service valve slowly clockwise sary and install the magnetic clutch on the com
toward the front seated position. pressor.
(6) When pressure drops to zero, stop the engine (1) Install the compressor on the mounting bracket.
and compressor and quickly finish front-seating the Tighten the bolts to 27 N*m (20 ft. lbs.) torque.
suction service valve. (2) Install the serpentine drive belt (refer to Group
(7) Front-seat the discharge service valve. 7, Cooling System for the proper procedure).
(8) Loosen the oil level check plug slowly to re (3) Tighten the serpentine drive belt to the speci
lease any internal pressure in the compressor. fied tension.
The compressor is now isolated from the remainder • New belt tension-800-900 N (180-200 lb-©.
of the system. • Used belt tension-623-712 N (140-160 lb-f).
The service valves can be removed from the com (4) Remove the tape or plastic plugs from all the
suction and discharge openings and install the ser
pressor.
vice valves on the compressor.
MOUNTING REMOVAL
(1) Insert the 2 pins of the front plate spanner into
any 2 threaded holes of the clutch front plate (Fig.
2). Hold clutch plate stationary. Eemove hex nut
with 19 mm (3/4 inch) socket (Fig. 2).
(2) Remove clutch front plate using puller. Align
puller center bolt to compressor shaft (Fig. 3). Thumb
tighten the puller bolts into the threaded holes.
Fig. 1 Compressor and Mounting Bracket

(5) Connect the clutch lead wire.
(7) Evacuate, charge and test the system for leaks.
J8924-18
MAGNETIC C L U T C H
The magnetic clutch consists of a stationary elec Fig. 3 Clutch Front Plate Removal
tro-magnetic coil and a rotating pulley and plate as
sembly. (3) Turn center bolt clockwise with 19 mm (3/4
The electromagnetic coil is retained on the com inch) socket until front plate is loosened.
pressor with a snap ring and is dimpled to maintain (4) Remove shaft key by lightly tapping it loose
its position. with a slot screwdriver and hammer (Fig. 4).
The pulley and plate assembly are mounted on the
compressor shaft.
When the compressor is not in operation, the pul
ley free wheels on the clutch hub bearing. When the
coil is energized the plate is magnetically engaged
with the pulley and turns the compressor shaft.
J8924-19
Fig. 4 Shaft Key Removal

Fig. 2 Hex Nut Removal
J H E A T I N G AND A I R CONDITIONING 24 - 1 9
(5) Remove the external front housing snap ring (7) Place rotor puller shaft protector over the ex
by using spread type snap ring pliers (Fig. 5). posed shaft.
(8) Install the puller plate and bolt (Fig. 7). 2 bolts
go through the plate and into the jaws. Finger
tighten bolts.
EXTERNAL
SNAP
RING
J8924-20
Fig. 5 External Snap Ring Removal

(6) Insert the lip of the jaws of the rotor puller into J8924-22
the snap ring groove exposed in the previous step
(Fig. 6). Fig. 7 Install Puller Plate
PULLER (9) Turn puller center bolt clockwise using 3/4 inch
SHAFT socket until rotor pulley is free.
PROTECTOR (10) Loosen coil lead wire from clip on top of com
pressor front housing (Fig. 8).
JAWS
J8924-21
Fig. 6 Install Shaft Protector
J8924-23
Fig. 8 Loosen Coil Lead Wire

24 - 20 H E A T I N G AND A I R CONDITIONING
J
(11) Using spread type snap ring pliers, remove
snap ring and field coil (Fig. 9).
J8924-26
Fig. 11 Tool Set Driver

(6) Place the tool set driver into the ring (Fig. 11).
Fig. 9 Snap Ring and Field Coil Removal (7) With a hammer, tap the end of the driver while
guiding the rotor to prevent binding. Tap until the
INSTALLATION rotor bottoms against the compressor front housing
(1) Install the field coil with the snap ring. hub. Listen for a distinct change of sound during the
(2) Place coil lead wire under clip on top of compres tapping process.
sor front housing and tighten the retaining screw. (8) Install external front housing snap ring with
(3) Support the compressor on the 4 mounting ears at spread type snap ring pliers.
the compressor rear. If a vise is being used, clamp only on (9) Install front plate assembly.
the mounting ears. Never clamp on the compressor body. • Check that original clutch shims are in place on
(4) Align rotor assembly squarely on the front compressor shaft.
housing hub. • Replace compressor shaft key.
(5) Using Rotor Installer Set, place the ring part of the • Align front plate keyway to compressor shaft key.
set into the bearing cavity (Fig, 10). Make certain the (10) Using shaft protector, tap front plate to shaft
outer edge rests firmly on the rotor bearing inner race. until it has bottomed to the clutch shims (Fig. 12).
Listen for a distinct change of sound during the tap
ping process.
(11) Replace shaft hex nut. Tighten the hex nut to
37 N*m (27 ft. lbs.) torque.
(12) Check air gap with feeler gauge (Fig. 13). The
specification is 0.406-0.787 mm (0.016-0.031 inch). If
air gap is not consistent around the circumference,
lightly pry up at the minimum variations. Lightly
tap down at points of maximum variation.
The air gap is determined by the spacer shims.
When installing the original or a new clutch as
sembly, try the original shims first. When install
ing a new clutch onto a compressor that
previously did not have a clutch, use 0.040, 0.020,
and 0.005 shims from the clutch accessory sack.
(13) If the air gap does not meet the specification
given, add or subtract shims as required.
J8924-25
Fig. 10 Rotor Installer Set
COMPRESSOR SHAFT SEAL
REMOVAL
(1) Insert the 2 pins of the front plate spanner into
any 2 threaded holes of the clutch front plate (Fig.
14). Hold clutch plate stationary. Remove hex nut
with 19 mm (3/4 inch) socket.
(2) Remove clutch front plate using puller (Fig. 15).
Align puller center bolt to compressor shaft. Thumb
tighten the 3 puller bolts into the threaded holes.
J8924-27
Fig. 12 Front Plate Installation
J8924-18
Fig. 15 Remove Clutch Front Plate

(3) Turn center bolt clockwise with 19 mm (3/4
inch) socket until front plate is loosened.
Shaft seal replacement should be done on the
bench. Never use any old parts of the shaft seal
assembly. Rebuild the complete assembly.
(4) Using either of the snap ring tools, insert the
tool points into the 2 holes of the felt ring metal re
J8924-28
tainer. Lift the felt ring out (Fig. 16).
Fig. 13 Check Air Gap (5) Remove the clutch shim. Use O-ring hook and
a small screwdriver to prevent shim from binding on
shaft (Fig. 17).
(6) Remove shaft seal seat retaining snap ring
with pinch type snap ring pliers (Fig. 18).
(7) Remove the shaft seal seat, using seal seat tool
(Fig. 19).
(8) Insert the Seal Remover and Installer Tool
against the seal assembly. Press down against the
seal spring and twist the tool until it engages the
slots of the seal cage (Fig. 20). Lift out seal assembly.
INSTALLATION
(1) Clean seal cavity thoroughly with a lint-free or
synthetic cloth and clean refrigerant oil. Then blow
out with dry pressurized vapor.
(2) Make sure all foreign substances are thor
oughly removed.
24 - 2 2 HEATING AND AIR CONDITIONING J
SNAP
FELT RING J8924-29
Fig. 16 Felt Ring Removal J8924-31
Fig. 18 Snap Ring Removal
CLUTCH
J8924-32
Fig. 17 Clutch Shim Removal Fig. 19 Shaft Seal Seat Removal

(3) Insert Seal Sleeve Protector over compressor may be necessary to lightly tap the snap ring to se
shaft (Fig. 21). curely position it in its groove.
(4) Do not touch the new seal lapping surfaces. Dip (8) Replace clutch spacer shims.
the mating surfaces in clean refrigerant oil before
(9) Tap new felt ring into place (Fig. 24).
proceeding.
(10) Align front plate keyway to compressor shaft
(5) Engage slots of Seal Remover and Installer to
key.
new seal cage and insert seal assembly firmly into
(11) Using shaft protector, tap front plate to shaft
place in the compressor seal cavity (Fig. 22). Twist
tool in opposite direction to disengage tool from seal until it has bottomed to the clutch shims. Listen for
cage. Remove tool. a distinct change of sound during the tapping pro
(6) Coat seal retainer with clean refrigerant oil. cess.
Use seal seat tool to install (Fig. 23). Press lightly (12) Replace shaft hex nut. Tighten the hex nut to
against seal. 37 N-m (27 ft. lbs.) torque.
(7) Install snap ring. Beveled edge lies outward (13) Check air gap with feeler gauge (Fig. 25). The
from compressor. Flat side lies toward compressor. It specification is 0.406-0.787 mm (0.016-0.031 inch). If
J8924-33
Fig. 20 Seal Assembly Removal
J8924-36
JS924-34
Fig. 23 Install Seal Retainer
Fig. 21 Insert Seal Sleeve Protector CYLINDER HEAD/¥ALVE PLATE
air gap is not consistent around the circumference,
lightly pry up at the minimum variations. Lightly REMOVAL
tap down at points of maximum variation. (1) Remove cylinder head bolts.
The air gap is determined by the spacer shims. (2) Using a small hammer and a gasket scraper
When installing the original or a new clutch as separate the cylinder head from the valve plate (Fig.
sembly, try the original shims first. When install 26).
ing a new clutch onto a compressor that (3) Visually inspect all parts for damage.
previously did not have a clutch, use 0.040, 0.020, (4) Separate the valve plate from the cylinder
and 0.005 shims from the clutch accessory sack. block (Fig. 27).
(14) If the air gap does not meet the specification
given, add or subtract shims as required.
24 - 2 4 HEATING A N i A l l CONDITIONING J
CYLINDER H E A D
VALVE PLATE
J8924-39
J8924-37
Fig. 24 Install New Felt Ring Fig. 26 Cylinder Head and Valve Plate
CYLINDER
BLOCK
FEELER
GAUGE
J8924-28
Fig. 25 Check Air Gap J8924-40

INSPECTION
Visually inspect the rear valves and discharge re Fig. 27 Valve Plate Removal
tainer for damage. Discard any component if any por
tion is damaged.
CLEANING
If valve plate and/or cylinder head are to be reused,
carefully remove gasket materials using the gasket
scraper. Do not damage cylinder block or valve plate
surfaces. \
HEATING AND AIR CONDITIONING 24 « 2§
INSTALLATION
When installing the cylinder head valve plate,
use the new gaskets in the parts kit.
(1) Coat new valve plate gasket with clean refrig
erant oil.
(2) Install valve plate gasket by aligning valve
plate gasket to locating pin holes and oil orifice in
cylinder block. (For easy reference, the gaskets have
a notch at the bottom outside edge).
(3) Install valve plate by aligning valve plate lo
cating pins to the pin holes in the block and position
valve plate.
(4) Install cylinder head and tighten bolts in order
to 32 N«m (24 ft. lbs.) torque (Fig. 28).
E8924-207
Fig. 28 Cylinder Head Bolt Torque Sequence

24 - 26 HEATING AND AIR CONDITIONING
CLIMATE CONTROL S Y S T E M - X J W E H I C L E S
INDEX
page page
A/C Recirculating Air Door Vacuum Motor Expansion (H) Valve 38
Replacement 35 Heater and A/C Control Panel Replacement .... 30
Blower Motor Resistors Replacement 39 Heater Control Cable Replacement 34
Blower Motor/Fan Replacement . 31 Heater Core 32
Condenser—4.0L Engines . 36 Heater Core Housing Replacement 33
Condenser/Receiver Drier—2.5L Engines . . . . . . . 35 Heater/Defroster/Instrument Panel Outlet Door
Defroster Duct Replacement 33
Description 26 Vacuum Motor Replacement 34
Evaporator Core 38 Receiver Drier—4.0L Engines 36
Evaporator/Blower Housing 36 Temperature Control Thermostat 39
DESCRIPTION the heater or air conditioning systems, except the

The Climate Control System combines air condi OFF mode. In this mode (OFF) the blower and the
tioning, heating and ventilating capabilities for vehi outside air are shut off.
cles equipped with air conditioning. Vehicles without The cooling unit is mounted on the dash panel and
air conditioning perform heating and ventilating the cooled air is discharged from the instrument
functions without the air conditioning evaporator. panel registers. The registers are adjusted to provide
Both systems consist basically of 2 parts: general or localized cooling.
• Blower and Air Inlet Assembly
• Heater Core and Air Distribution Assembly SIGHT GLASS
These assemblies, initially installed as a single The sight glass is located on top of the receiver/
unit, may be removed separately from under the in drier. The sight glass provides a visual check of the
strument panel as required for service. system refrigerant level. A continuous stream of bub
bles will appear in the sight glass when the system
HEATER SYSTEM
charge is low. Bubbles will not appear when the sys
The heater system is a blend air type. Outside air
tem is fully charged.
is heated and then blended in varying amounts with
cooler outside air to obtain the desired discharge LOW PRESSURE SWITCH
temperature. A heater coolant valve provides full
The low pressure switch disengages the magnetic
flow to the heater core for all heating modes. The
clutch if the pressure in the system drops below 193
heater coolant valve remains closed for the ventila
kPa (28 psi). This will occur with a loss in refriger
tion mode, allowing discharge air to approach the
ant or with cold ambient temperature.
outside ambient air temperature.
AIR CONDITIONING SYSTEM HEATER VALWE

The air conditioning system has an evaporator to The heater valve regulates coolant flow to the
cool and dehumidify the incoming outside air prior to heater core. It requires vacuum to shut off flow to
blending with the heated air. The evaporator is in the heater core.
operation during the A/C mode and also in the de These vehicles are equipped with a bypass-type
frost mode for defogging purposes. The evaporator is heater water valve. When the heater valve is closed,
not in operation at ambient temperatures below ap coolant flow to the heater core is bypassed back to
proximately -1°C (30°F). To maintain minimum evap the engine. When the heater valve is open, coolant is
orator temperature, a fixed thermostat setting switch directed through the heater core and back to the en
cycles the compressor clutch. The blower is operating gine.
J HEATING AND AIR CONDITIONING 24 - 2S
INSTALLATION
When installing the cylinder head valve plate,
use the new gaskets in the parts kit.
(1) Coat new valve plate gasket with clean refrig
erant oil.
(2) Install valve plate gasket by aligning valve
plate gasket to locating pin holes and oil orifice in
cylinder block. (For easy reference, the gaskets have
a notch at the bottom outside edge).
(3) Install valve plate by aligning valve plate lo
cating pins to the pin holes in the block and position
valve plate.
(4) Install cylinder head and tighten bolts in order
to 32 N*m (24 ft. lbs.) torque (Fig. 28).
18924-207
Fig. 28 Cylinder Head Bolt Torque Sequence

CLIMATE CONTROL S Y 8 T E M - X J WEHICLES
INDEX
page page
A/C Recirculating Air Door Vacuum Motor Expansion (H) Valve 38
Replacement 35 Heater and A/C Control Panel Replacement . . . . 30
Blower Motor Resistors Replacement . 39 Heater Control Cable Replacement 34
Blower Motor/Fan Replacement . . . . . . . . . . . . . . 31 Heater Core 32
Condenser—4.0L Engines 36 Heater Core Housing Replacement 33
Condenser/Receiver Drier—2.5L Engines 35 Heater/Defroster/Instrument Panel Outlet Door
Defroster Duct Replacement 33
Description 26 Vacuum Motor Replacement 34
Evaporator Core 38 Receiver Drier—4.0L Engines 36
Evaporator/Blower Housing 36 Temperature Control Thermostat 39
DESCRIPTION the heater or air conditioning systems, except the

The Climate Control System combines air condi OFF mode. In this mode (OFF) the blower and the
tioning, heating and ventilating capabilities for vehi outside air are shut off.
cles equipped with air conditioning. Vehicles without The cooling unit is mounted on the dash panel and
air conditioning perform heating and ventilating the cooled air is discharged from the instrument
functions without the air conditioning evaporator. panel registers. The registers are adjusted to provide
Both systems consist basically of 2 parts: general or localized cooling.
• Blower and Air Inlet Assembly
• Heater Core and Air Distribution Assembly SIGHT GLASS
These assemblies, initially installed as a single The sight glass is located on top of the receiver/
unit, may be removed separately from under the in drier. The sight glass provides a visual check of the
strument panel as required for service. system refrigerant level. A continuous stream of bub
bles will appear in the sight glass when the system
HEATER SYSTEM
The heater system is a blend air type. Outside air
tem is fully charged.
is heated and then blended in varying amounts with
cooler outside air to obtain the desired discharge LOW PRESSURE SWITCH
temperature. A heater coolant valve provides full The low pressure switch disengages the magnetic
flow to the heater core for all heating modes. The
clutch if the pressure in the system drops below 193
heater coolant valve remains closed for the ventila
kPa (28 psi). This will occur with a loss in refriger
tion mode, allowing discharge air to approach the
ant or with cold ambient temperature.
outside ambient air temperature.
AIR CONDITIONING SYSTEM HEATER VALVE

The air conditioning system has an evaporator to The heater valve regulates coolant flow to the
cool and dehumidify the incoming outside air prior to heater core. It requires vacuum to shut off flow to
blending with the heated air. The evaporator is in the heater core.
operation during the A/C mode and also in the de These vehicles are equipped with a bypass-type
frost mode for defogging purposes. The evaporator is heater water valve. When the heater valve is closed,
not in operation at ambient temperatures below ap coolant flow to the heater core is bypassed back to
proximately -1°C (30°F). To maintain minimum evap the engine. When the heater valve is open, coolant is
orator temperature, a fixed thermostat setting switch directed through the heater core and back to the en
cycles the compressor clutch. The blower is operating gine.
H E A T I N G A N D A I R CONDITIONING 24 - 27
AIRFLOW DIAGRAM
2m5 n ^ d i Ixmff LLLLJ,

W
r u L - BLEND DOOR
A - O U T S I D E AIR INLET M- EVAPORATOR CORE
I - COWL N - R E C I R C U L A T I O N AIR INLET
C - D A S H PANEL P - RECIRCULATION D O O R
D - W A T E R VALVE R - FLOOR OUTLET
E - B L O W E R ASSEMBLY S - LEFT H A N D REGISTER
F - DEFROSTER T - LEFT H A N D LAP COOLER
G- HEATER CORE U - L E F T CENTER REGISTER
H - DEFROSTER DOOR V - RIGHT CENTER REGISTER
J - FLOOR DOOR W- RIGHT H A N D REGISTER J8924-81
K - PANEL DOOR
24 - 28 HEATING AND A I R CONDITIONING J
HEATING SCHEMATIC
HEATER CONTROL U N I T
HEATER SYSTEM OPERATION
Mode
Panel Floor Defrost Water
Lever Blower
Door Door Door Valve
Position Air Discharge Speeds
Off Closed None Closed Closed Closed Closed
Vent Panel Registers 4 Open Closed Closed Closed
Panel Registers and Floor With Open

Bi-Level 4 Open Open Bleed
D e l Bleed (1)
Open
Heat Floor With Def. Bleed 4 Closed Open Bleed
in
Open
Defroster 4 Closed Closed Open
(1)
(1) W A T E R VALVE CLOSES IN FULL "COOL" TEMPERATURE LEVER POSITION.
HEATER CONTROL SYSTEM

V A C U U M SCHEMATIC
W A T E R VALVE
J8924-82
H E A T I N G AND A I R CONDITIONING 2 4 - 29
AIR CONDITIONING SCHEMATIC
A/C C O N T R O L U N I T
-AIR CONDITIONING -
HI OFF MAX NORM il-LEVfl VINT NEAT
A/C S Y S T E M O P E R A T I O N
Mode
Lever Blower Recirc. Panel Floor Defrost A/C Water
Position Air Discharge Speeds Door Door Door Door Cmp. Valve
Indeter
Off Closed None Recirc. Open Open Off Closed
minate
Max Panel Registers Open

4 Recirc. Open Bleed Closed On
A/C With Floor Bleed (1)
Norm Panel Registers Open

4 Outside Open Bleed Closed On
A/C With Floor Bleed (1)
Panel Registers and Open
Bi-Level 4 Outside Open Open Bleed On
Floor With Def. Bleed (D
Panel Registers Open

Vent 4 Outside Open Bleed Closed Off
With Floor Bleed (D
Open
Heat Floor W t h Def. Bleed 4 Outside Closed Open Bleed Off
ID
Open
Def. With Floor Bleed 4 Outside Closed Bleed Open On
in
0) W A T E R VALVE C L O S E S I N F U L L COOL T E M P E R A T U R E L E V E R P O S I T I O N .
AIR CONDITIONING CONTROL SYSTEM V A C U U M SCHEMATIC

W A T E R VALVE ~_ BLOWER SOURCE
ITXV j j ASSEMBLY £1
DEFROSTER CHECK
VALVE
RESERVOIR
DEFROST "OUTSIDE AIR

DOOR
RECIRC
FLOOR J F L O O R DOOR
DOOR
'RECIRC.
AIR
GREEN BLUE
ORANGE
BROWN
VIOLET
WHITE
1
A©1 10I
NV = N O VACUUM
PV = PARTIAL VACUUM
V = FULL VACUUM
©•3 n©-
s®
BLACK
i t J9124-29
24 - 30 H E A T I N G A N D A I R CONDITIONING
H E A T E R AND A/C C O N T R O L P A N E L R E P L A C E M E N T ANTENNA

(1) Disconnect negative cable from battery. LEAD
(2) Remove the instrument panel bezel attaching
screws and remove the instrument panel bezel (Fig.
1). Bezel is snap fit at locations shown.
(3) Remove the radio attaching screws (Fig. 2).
BEZEL
ATTACHING
SCREWS SNAP FIT GROUND ELECTRICAL
LOCATION LEAD CONNECTOR J898F-2
Fig. 3 Radio Wiring Harness
SNAP FIT
LOCATIONS
J898E-9
Fig. 11nstrument Bezel
C O N T R O L PANEL
M O U N T I N G SCREWS J8924-84
Fig. 4 Control Panel Mounting Screws
pjjjjBffljij
i
J898F-1
Fig. 2 Radio Mounting Screws

(4) Disconnect the radio electrical connector,
ground lead and antenna lead (Fig. 3). ELECTRICAL
CONNECTORS
(5) Remove the A/C-heater control panel screws J8924-85
(Fig. 4).
(6) Remove the electrical connectors (Fig. 5). Fig. 5 Electrical Connectors
J HEATING AND AIR CONDITIONING 24 - 3 1
(7) Disconnect the vacuum hoses by releasing the

locking tabs (Fig. 6).
(8) Remove the control cable locking tab by using
a screwdriver to release the tab (Fig. 7).
Fig. 8 Control Cable and Ring

BLOWER MOTOR/FAN REPLACEMENT
The blower motor and fan are accessible and
may be removed from the engine compartment.
Fig. 6 Vacuum Hose Connector 2«5L ENGINE
(1) Disconnect the blower motor wires (Fig. 9).
(2) Remove the blower motor and fan assembly
mounting screws (Fig. 10).
(3) Remove the blower motor and fan assembly.
(4) Remove the blower motor fan from the motor
shaft for access to the motor attaching nuts (Fig. 11).
Fig. 7 Control Cable Locking Tab

(9) Remove the ring on the end of the control cable
from the arm on the bottom of the control panel (Fig.
8).
To Install the A/C-heater control panel, reverse the
removal procedures.
Fig. 9 Blower Motor Connector
To install the blower fan and motor, reverse the re 18mm B L O W E R FAN
moval procedures. (0.71 INCH) Q
4.0L ENGINE
(1) Remove the coolant bottle retaining strap and
move bottle aside.
(2) Remove the coolant bottle bracket.
(3) Remove the anti-lock brake pump and bracket
as an assembly (if equipped) and move the pump
aside.
(4) Disconnect the blower motor wires (Fig. 9).
(5) Remove the blower motor and fan assembly
mounting screws (Fig. 10).
MOTOR A B FLAT
SHAFT SURFACE
V
^.RETAINER
FAN H U B ^ ^ CLIP
J9124-30
Fig. 11 Blower Fan
J8924-91
Fig. 10 Blower Motor Mounting Screws

(6) Remove the blower motor and fan assembly.
(7) Remove the blower motor fan from the motor
shaft for access to the motor attaching nuts (Fig. 11).
To install the blower fan and motor, reverse the re
moval procedures. The ears (A) and (B) of the re
tainer clip must be over the flat surface on the
motor shaft (Fig. 11).
HEATER CORE
REMOVAL
(1) Drain the radiator.
(2) Disconnect the heater hoses at the heater core HEATER
inlet and outlet tubes. CORE RETAINING
(3) Remove the evaporator/blower housing. SCREWS J8924-92
(4) Remove the retaining screws and remove the Fig. 12 Heater Core
heater core by pulling it straight out of the housing
(Fig. 12). (3) Cement the seal into place in order to keep it
from moving when the blower assembly is installed.
INSTALLATION (4) Connect the heater hoses to the heater core.
(1) Install the heater core into the housing and in (5) Fill the cooling system.
stall the screws.
(2) Install the evaporator/blower housing.
H E A T E R CORE HOUSING R E P L A C E M E N T
(1) Remove the evaporator/blower housing,
(2) Remove the heater core,
(3) Remove the defroster duct.
(4) Disconnect the vacuum hoses from the heater
core housing vacuum motors.
(5) Remove the heater housing retaining nuts in
the engine compartment. Remove the heater core
housing.
(6) Transfer the vacuum motors, etc. to the re
placement housing.
To install the heater core housing, reverse the re
moval procedure.
DEFROSTER DUCT REPLACEMENT
REMOVAL
(2) If equipped with center console remove the con
sole as follows:
(a) MANUAL TRANSMISSION-Remove shift
knob, boot and bezel.
(b) AUTOMATIC TRANSMISSION-Remove
shift handle by pulling up. Remove the shift bezel.
(c) POWER MIRRORS-Pry mirror switch out of
console cover (Fig. 13). Disconnect switch connector
(Fig. 14).
(d) Remove console cover screws (Fig. 14).
Fig. 13 Power Mirror Switch

(e) Remove console cover from base (Fig. 15).
(f) Remove console base (Fig. 15).
(4) Remove the left kick panel.
(5) Remove the instrument panel retaining bolt.
(6) Remove the instrument panel retaining bolts
located at the steering column.
(7) Remove the right and left A-pillar trim.
(8) Remove the defroster bezel attaching screws Fig. 15 Console Cover and Base
and bezel (Fig. 16).
(11) Pull the instrument panel, approximately 3
(9) Remove the instrument panel retaining screws.
inches, away from the dash panel.
(10) Lower the steering column.
HEATER CONTROL CABLE REPLACEMENT
(1) Remove the heater control panel.
(2) Remove the clip and the cable self-adjusting
clip from the blend air door lever at the bottom of
the evaporator/blower housing (Fig. 17). Then re
move the cable by squeezing the tabs with needle
nose pliers being careful not to break the housing.
To install the heater control cable, reverse the re
moval procedure.
J8924-93
Fig. 16 Defroster Bezel

(12) Remove the defroster duct retaining screws.
Remove the defroster duct.
(13) Disconnect the hoses.
INSTALLATION
(1) Connect the hoses.
(2) Install the defroster duct. Install the defroster
duct retaining screws.
(3) Position the instrument panel into the dash
Fig. 17 Heater Control
panel.
(4) Position the steering column. HEATER/DEFROSTER/INSTRUMENT PANEL OUTLET
(5) Install the instrument panel retaining screws. DOOR VACUUM MOTOR REPLACEMENT
(6) Install the defroster bezel attaching screws and (1) If equipped with center console remove the con
bezel. sole as follows:
(7) Install the right and left A-pillar trim. (a) MANUAL TRANSMISSION-Remove shift
(8) Install the instrument panel retaining bolts lo knob, boot and bezel.
cated at the steering column. Tighten the steering .(b) AUTOMATIC TRANSMISSION-Remove
column retaining nuts to 27 N»m (20 ft. lbs.) torque. shift handle by pulling up. Remove the shift bezel.
(9) Install and tighten the instrument panel re (c) POWER MIRRORS-Pry mirror switch out of
taining bolt. console cover (Fig. 13). Disconnect switch connector
(10) Install the left kick panel. (Fig. 14).
(11) Install the lower instrument panel. (d) Remove console cover screws (Fig. 14).
(12) If equipped with center console, install the (e) Remove console cover from base (Fig. 15).
console as follows: (f) Remove console base.
(a) Install console base. (2) Remove the lower instrument panel.
(b) Install console cover to base. ' (3) Disconnect the vacuum hose(s) from the vac
(c) Install and tighten console cover screws. uum motor.
(d) POWER MIRRORS-Snap mirror switch into (4) Remove the vacuum motor attaching nuts and
the console cover. Connect switch connector. remove the vacuum motor from the bracket.
(e) MANUAL TRANSMISSION-Install shift (5) Remove the vacuum motor linkage retaining
knob, boot and bezel. clip and remove the rod from the door actuating le
(f) AUTOMATIC TRANSMISSION-Install the ver (Fig. 18).
shift bezel. Install shift handle by pushing down. To install a vacuum motor, reverse the removal
(13) Connect negative cable to battery. procedure.
J H E A T I N G AND AIR CONDITIONING 24 - 3 1
VACUUM MOTOR
ATTACHING NUTS
RETAINING
CLIP
PANEL
RETAINING
CLIP
DEFROSTER
DOOR
LINKAGE
„ .J ¥/
VACUUM MOTOR
ATTACHING N U T S
/
DEFROSTER
VACUUM
RETAINING MOTOR ATTACHING J9124-55
CLIP NUTS J8924-96
Fig. 20 Vacuum Door Motor
Fig. 18 Vacuum Motor
CONDENSER/RECEIVER D R I E R — 2 . 5 L ENGINES
A/C RECIRCULATING AIR DOOR VACUUM MOTOR
REPLACEMENT REMOVAL
(1) Remove the vacuum motor cover (Fig. 19). (1) Drain the radiator.
(2) Disconnect the vacuum hose (Fig. 20). (2) Disconnect the fan shroud and the radiator hoses.
(3) Remove the actuating rod clip and disengage (3) Disconnect the transmission cooler lines (if
the rod from the door lever. equipped with automatic transmission).
(4) Remove the vacuum motor retaining nuts and (4) Evacuate the A/C system. Disconnect the A/C
then remove the vacuum motor. hoses from the condenser.
To install the motor, reverse the removal proce (5) Unplug the harness from the low pressure
dures. switch (Fig. 21).
(6) Remove the radiator and condenser as an as
sembly.
(7) Remove the retaining bolts and separate the
condenser from the radiator.
(8) Remove the receiver/drier from the condenser.
Keep receiver/drier openings plugged at all
times to prevent moisture from entering the re
ceiver/drier.
INSTALLATION
(1) Remove the plugs from the receiver/drier open
ings. Install receiver/drier into the condenser.
(2) Install the condenser to the radiator. Tighten
the retaining bolts.
(3) Install the radiator and condenser as an assem
bly (refer to Group 7, Cooling System for the proper
procedure).
(4) Plug the harness into the low pressure switch
(Fig. 21).
(5) Connect the A/C hoses to the condenser.
J9l 24-54
(6) Connect the transmission cooler lines (if
equipped with automatic transmission).
Fig. 19 Vacuum Door Motor Cower (7) Connect the fan shroud and the radiator hoses.
CONDENSER (2) Unplug the harness from the low pressure
switch.
(3) Remove the nut attaching the receiver dryer to
the side sill weld stud.
(4) Remove the receiver dryer.
J9124-56
Fig. 21 Condenser Receiver Drier—2.5L Engine Fig. 22 Receiver Dryer—4.0L Engine

(8) Add 1 ounce of refrigerant oil- to the system if INSTALLATION
the condenser was replaced. (1) Install the receiver dryer.
(9) Fill the cooling system. (2) Install and tighten the nut attaching the re
(10) Charge the A/C system. ceiver dryer to the side sill weld stud.
(3) Plug the harness to the low pressure switch.
CONDENSER—4.OL ENGINES (4) Remove the plugs the openings. Connect the
REMOVAL A/C hoses to the receiver dryer.
(1) Disconnect the fan shroud and electric fan from (5) Charge the A/C system.
the radiator.
(2) Remove the upper crossmember and bracket, EVAPORATOR/BLOWER HOUSING
(3) Evacuate the A/C system, disconnect the A/C REMOVAL
hoses from the condenser and plug the openings. (1) Disconnect negative cable from battery.
(4) Remove the attaching hardware and brackets (2) Discharge the A/C system as described in this
securing the condenser to the radiator. section and disconnect the A/C hoses from the expan
(5) Remove the condenser. sion valve.
(3) Disconnect the blower motor wires and the vent
INSTALLATION
tube.
(1) Install the condenser.
(2) Remove the plugs from the openings. Connect
sole as follows:
the A/C hoses to the condenser.
(3) Install the upper crossmember and bracket.
(4) Connect the fan shroud and electric fan to the
(b) AUTOMATIC TRANSMISSION-Remove
radiator.
shift handle by pulling up. Remove the shift bezel.
(5) Add 1 ounce of refrigerant oil to the A/C sys
(c) POWER MIRRORS-Pry mirror switch out of
tem if the condenser was replaced.
console coyer (Fig. 13) and disconnect switch con
(6) Charge the A/C system.
nector (Fig. 14).
RECEIVER D R I E R - 4 . 0 L ENGINES (d) Remove console cover screws (Fig. 14).
(e) Remove console cover from base (Fig. 15).
REMOVAL (f) Remove console base.
(1) Evacuate the A/C system, disconnect the A/C (5) Remove the lower instrument panel.
hoses from the receiver dryer and plug the openings
(Fig. 22).
HEATING A N D A I R CONDITIONING 24 - 37
J
(6) Disconnect the electrical connections at the (10) Remove the housing attaching nuts from the
blower motor resistors and the A/C thermostat. Dis studs on the engine compartment side of the dash
connect the vacuum hose at the vacuum motor (Fig. panel (Fig. 25). Remove the evaporator drain tube.
23).
J9124-59
J9124-58 Fig. 25 Evaporator Housing Mounting

(11) Remove the right kick panel and then remove
Fig. 23 Evaporator Housing Components the instrument panel support bolt.
(7) Cut the plastic retaining strap that retains the (12) To disengage the housing studs from the dash
evaporator/blower housing to the heater core housing panel, gently pull out on the right side of the dash.
(Fig. 24). Then rotate the housing downward and toward the
rear of the vehicle . Remove the evaporator/blower
housing.
INSTALLATION
(1) Position the evaporator/blower housing into
place, being sure to line up the housings using the
provided alignment tabs (Figs. 26 and 27).
(2) Install the housing retaining screws and the
rear housing clip (Fig. 25).
CAUTION: When installing the evaporator/blower

housing, DO NOT trap wires between the housing
fresh air inlet and the dash panel (right side of
housing).
(3) Install the housing retaining nuts on the en

gine compartment side of the dash panel (Fig. 25).
(4) Connect the A/C hoses to the expansion valve
and connect the heater blower motor wires.
(5) Attach the wire connections at the blower mo
CLIP
tor resistors and the A/C thermostat (Fig. 23).
Fig. 24 Evaporator Housing (6) Connect the vacuum hose at the vacuum motor
and attach the heater control cable.
(8) Disconnect and remove the heater control ca (7) Install the instrument panel bolt and the kick
ble. panel.
(9) Remove the clip at the rear of the blower hous (8) Install the lower instrument panel and screws.
ing flange and remove the retaining screws. (9) Install the console (if equipped).
24 - 3 8 HEATING AND A I R CONDITIONING J
TOP OF HOUSING
ALIGNMENT
TAB
J9124-60
Fig. 28 Top of Housing

J8924-103 lift the evaporator out of the housing (Fig. 29).
(5) Remove the expansion valve from the evapora
Fig. 26 Evaporator Housing Alignment Tab tor.
EVAPORATOR
f(
EVAPORATOR
RETAINING
SCREWS
ALIGNMENT
TABS
V
J9124-62
J8924-104 Fig. 29 Evaporator

INSTALLATION
Fig. 27 Evaporator Housing (1) Install the expansion valve into the evaporator.
(10) Connect negative cable to battery. (2) Position the evaporator in the housing. Install
(11) Evacuate and charge the A/C system as out and tighten the evaporator retaining screws (Fig.
lined in this section. 29).
(12) Start the vehicle and check for proper opera (3) Install the thermostatic switch and capillary
tion at all vacuum motors. tube. Install the top of the evaporator housing.
(4) Position the top of the evaporator housing in
EVAPORATOR CORE place. Install and tighten the top housing retaining
screws.
REMOVAL (5) Install the evaporator/blower housing.
(1) Remove the evaporator/blower housing. (6) Add 1 ounce of refrigerant oil to the air condi
(2) Remove the top housing retaining screws. Re tioning system if the evaporator was replaced.
move the top of the evaporator housing (Fig. 28).
(3) Remove the thermostatic switch and capillary EXPANSION (H) VALVE
tube after removing the top of the evaporator hous
ing. REMOVAL
(4) Remove the evaporator retaining screws and (1) Discharge the A/C system.
J H E A T I N G A N D A I R CONDITIONING 24 - 39
(2) Remove the coolant bottle and bracket. (b) AUTOMATIC TRANSMISSION—Remove
(3) Disconnect A/C hoses from the expansion valve shift handle by pulling up. Remove the shift bezel.
(Fig. 30). (c) POWER MIRRORS-Pry mirror switch out of
(4) Disconnect the expansion valve from the evap console cover (Fig. 31) and disconnect switch con
orator core inlet and outlet tubes. Remove the expan nector (Fig. 32).
sion valve. (d) Remove console cover screws (Fig. 32).
Fig. 31 Power Mirror Switch
J9124-61
Fig. 30 Expansion (H) Valve

INSTALLATION
(1) Install the expansion valve. Connect the expan
sion valve to the evaporator core inlet and outlet
tubes.
(2) Connect A/C hoses to the expansion valve (Fig.
30).
(3) Install the coolant bottle and bracket.
(4) Charge the A/C system.
(5) Preform the leak test.
B L O W E R MOTOR R E S I S T O R S R E P L A C E M E N T
(1) Remove the vacuum motor cover retaining
screw and lower the cover.
(2) Remove the blower motor resistor connector, re
move the resistor retaining screws, and then remove
the resistor.
To install the blower motor resistor reverse the re
moval procedures. Fig. 32 Console Cover Screws and Power Mirror
Switch Connector
T E M P E R A T U R E CONTROL T H E R M O S T A T (e) Remove console cover from base (Fig. 33).
(f) Remove console base (Fig. 33).
REMOVAL
(4) Pull the rosebud terminal out of the housing
(Fig. 34).
sole as follows:
(5) Disconnect the electrical connection.
(6) Remove the wires from the retaining clip.
(7) Carefully remove the thermostat probe/thermo

stat electronic cycling switch from the tube guide
hole (Fig. 34).
INSTALLATION
(1) Carefully insert the thermostat probe into the
tube guide hole until the thermostat electronic cy
cling switch body butts up against the housing.
(2) Connect the rosebud terminal (Fig. 34).
(3) Snap the terminal into the hole in the housing.
(4) Install the wires into the retaining clip.
(5) Reverse the removal procedures for the remain
der of the installation.
CLIMATE CONTROL SYSTEM—YJ VEHICLES
INDEX
page page
A/C Blower Motor 47 Fresh Air Door Vacuum Motor 45
A/C Condenser 46 Fresh Air Intake Duct . 45
A/C Control Panel 45 Fresh Air Ventilation . 42
Blower Motor (Heating) 44 Heater Control Panel Replacement 42
Blower Motor/Air Door Motor Switch Replacement . 42 Heater Core and Housing 44
Defroster Nozzle and Duct 44
Heater/Defroster Operation 41
Description (Air Conditioning) 45
Description (Heating) 41 Receiver-Drier Replacement 46
Evaporator and Housing 46 Sight Glass 45
Expansion (H) Valve . 47 Vent Door Control Cables . . . . . . . . . . . . . . . . . . 42
DESCRIPTION (HEATING) The temperature control lever (Fig. 1) determines

A blend-air heating system is used in YJ vehicles. air flow through the heater core. The lever operates
The blend-air system provides a constant flow of en the heater housing blend-air door which controls air
gine coolant through the heater core. flow through the core.
The temperature of heated air entering the passen The blower motor is operated by the control switch
ger compartment is controlled by regulating the (Fig. 1). The switch provides 3 blower speeds for in
quantity of air flow through the heater core. This is creased air flow in heat or defrost mode.
accomplished by blending a controlled amount of un-
heated air from outside the vehicle with heated air HEATING
from the heater core. Maximum air flow and heater output occurs when
the air control lever is in HEAT position and the
HEATER/DEFROSTER OPERATION temperature control lever is in WARM position. The
The heater core is connected to the engine cooling blend-air door is closed and all intake air is directed
system. It operates on the circulation of heated en through the heater core in this operating mode (Fig.
gine coolant through the core and a supply of fresh 2).
air drawn in through the intake grille on the cowl. Temperature regulation of the heated air is deter
Engine coolant flows through the heater core at all mined by position of the temperature control lever.
times. Moving the control lever from WARM to an in-be
The heater controls are on the heater control panel tween position, opens the blend-air door in the heater
(Fig. 1). housing. As the door opens, unheated outside air is
drawn into the system and blended with heated air
AIR C O N T R O L HEATER C O N T R O L from the core.
LEVER PANEL
DEFROSTING
The heater housing contains a defroster door to di
vert heated air to the defroster duct and windshield
outlets (Fig. 2). Defrost air flow is controlled by the
air control lever.
For defroster operation, the air control lever must
be moved to the defrost detent. The detent is identi
BLOWER MOTOR TEMPERATURE CONTROL fied by the defrost symbol on the control panel. In
CONTROL SWITCH LEVER J9124-34
this position, the defroster door in the heater housing
diverts all heated air (from the core) to the defroster
Fig. 1 Heater Control Panel duct windshield outlets.
The air control lever (Fig. 1) operates a door in the If the air control lever is moved to any position be
fresh air intake duct. The door controls the amount tween the heat and defrost detents, the defroster door
of fresh air flow into the heater housing and core. does not close completely. In this mode, the door re
When the lever is in the OFF position, the intake mains partially open causing heated air to be divided
door is closed preventing air flow into the housing. equally between the heat and defrost outlets.
24 - 42 HEATING AND AIR CONDITIONING 4
DEFROSTER D U C T
DEFROSTER N O Z Z L E
CABLE
HEATER H O U S I N G COVER
J9124-35
Fig. 2 Heating System Components

FRESH AIR VENTILATION B L O W E R M O T O R / A I R DOOR M O T O R S W I T C H
The fresh air ventilating system (Fig. 3) is oper REPLACEMENT
ated by the air control lever. When the lever is (1) Remove the heater control panel (Fig. 5).
moved to VENT position, outside air from the cowl (2) Remove the air door motor switch.
intake flows into the heater housing. Incoming air is (3) Remove the control knob from the blower
directed into the vehicle interior through vent doors switch.
in the housing. (4) Remove the screws that attach the switch to
A door in the intake duct controls air flow into the the control panel.
duct. The door is operated by a vacuum motor. The (5) Remove the switch from the control panel.
motor is controlled by a vacuum switch in the heater To install the switches, reverse the removal proce
control panel. The vent air doors are opened and dures.
closed by a cable and linkage operated by the air
control lever. Fresh air intake occurs only when the VENT DOOR CONTROL CABLES
lever is in the VENT position.
REMOVAL
HEATER CONTROL PANEL REPLACEMENT (1) Disconnect the cable from the vent door.
(1) Remove the instrument cluster bezel attaching (2) Disconnect the cable from the heater control
screws (Fig. 4). panel lever. The cables are attached to the control
(2) Remove the instrument cluster bezel. panel levers with plastic tabs. Press the tabs to
(3) Remove the screws attaching the heater control gether and lift the cable upward to disengage it from
panel to the instrument panel. the lever.
(4) Slide the control panel outward and disconnect (3) Remove the cable. The clip on the cable wire
the cables, vacuum hoses and electrical wires from has 2 functions. It attaches the cable to the vent door
the control panel. and is also the self adjusting mechanism. Because
(5) Remove the control panel. the left cable operates the right cable, the cables
To install the control panel, reverse the removal must be installed as outlined to maintain the self ad
procedures. justing feature and ensure proper vent door opera
tion.
4 HEATING AND AIR CONDITIONING 24 - 4 3
AIR INTAKE GRILLE
DRAIN HOSE
FRESH A I R INTAKE DUCT
CLAMP
INSULATOR
AIR DOOR V A C U U M M O T O R
V A C U U M LINES
J9124-36
Fig. 3 Fresh Air intake System Components

HEATER
CONTROL
PANEL
BEZEL J9124-37
Fig. 4 Instrument Cluster Bezel

INSTALLATION
(1) To install the cables, connect the cables to the
heater control panel.
(2) Connect the right vent door cable. Do not con CONTROL
KNOB
nect the left door cable at this time. AIR DOOR
SWITCH
(3) Open and close the right vent door (one time) MOTOR
MOUNTING
SWITCH
using the air control lever on the heater control SCREWS
panel. J8924-70
(4) Connect the left vent door cable.

Fig. 5 Control Switches
(5) Open and close both vent doors with the air
control lever. Verify that both vent doors open at the
same time.
HEATER CORE AND HOUSING INSTALLATION

(1) Position the blower motor into the housing.
REMOVAL (2) Install and tighten the blower motor-to-heater
housing attaching screws/nuts.
WARNING: H O T ENGINE COOLANT CAN C A U S E (3) Install the heater housing.
S E V E R E B U R N S . DO N O T O P E N T H E R A D I A T O R (4) Check blower motor and heater operation.
DRAIN COCK W H E N T H E COOLING S Y S T E M I S
H O T AND P R E S S U R I Z E D - A L L O W T H E COOLANT DEFROSTER NOZZLE AND DUCT
T O D E C R E A S E T O ROOM T E M P E R A T U R E B E F O R E
STARTING REPAIR OPERATIONS. REMOVAL
(1) Drain approximately 1.9 liters (2 qts) of coolant WARNING: H O T ENGINE COOLANT CAN C A U S E
from the radiator. Drain the coolant into a clean con S E V E R E B U R N S . DO N O T O P E N T H E R A D I A T O R
tainer. DRAIN COCK W H E N T H E COOLING S Y S T E M I S
(2) Disconnect the heater hoses. H O T AND P R E S S U R I Z E D . A L L O W T H E COOLANT
(3) Disconnect the vent door cables. T O D E C R E A S E T O ROOM T E M P E R A T U R E B E F O R E
(4) Disconnect the blower motor wire. STARTING REPAIR OPERATIONS.
(5) Disconnect the defroster duct.
(6) Remove the nuts that attach the heater hous (1) Drain approximately 1.9 liters (2 qts) of coolant
ing studs to the engine compartment side of the dash from the radiator. Drain the coolant into a clean con
panel. tainer.
(7) Remove the heater housing assembly by tilting (2) Disconnect the heater hoses.
it downward, to disengage it from the defroster duct. (3) Remove the nuts attaching the heater housing
Pull it rearward and out from under the instrument studs to the engine compartment side of the dash
panel. paneL
(8) Remove the heater hosing cover from the hous (4) Disconnect the speedometer cable.
ing. (5) Remove the glove box.
(9) Remove the heater core from the housing. (6) Tilt the heater housing back and pull it rear
ward and out from under the instrument panel.
INSTALLATION (7) Disconnect the vent control cables.
(1) Install the heater core in the housing and in (8) Remove the fresh air intake grille from the
stall the cover on the housing. cowl.
(2) Position the heater housing on the dash panel. (9) Remove the fresh air intake duct.
Be sure the housing studs all extend through the (10) Lower the windshield.
dash panel. (11) Remove the defroster nozzle attaching screws
(3) Install the seals on the heater core outlet and and remove the nozzle and duct.
inlet tubes and over the blower motor housing.
(4) Install the attaching nuts on the housing studs. INSTALLATION
(1) Install the defroster nozzle and duct.
CAUTION: Do not over tighten the attaching nuts. (2) Raise and secure the windshield.
T h e housing could become distorted causing air (3) Install the fresh air intake duct.
leaks and improper heater door operation. Tighten (4) Install the fresh air intake grille on the cowl.
the nuts alternately and evenly until 2 stud threads (5) Install the vent cables.
are visible beyond each nut. (6) Position the heater housing on the dash panel.
Be sure all the housing studs extend through the
(5) Connect the defroster duct to the housing. dash panel.
(6) Connect the blower motor wire. (7) Install the seals on the blower motor and the
(7) Connect the vent door control cables. heater core inlet and outlet tubes.
(8) Connect the heater hoses. (8) Install the attaching nuts on the housing studs.
(9) Fill and bleed the cooling system.
(10) Check system operation. CAUTION: Do not over tighten the attaching nuts.
T h e housing could become distorted causing air
BLOWER MOTOR (HEATING) leaks and improper heater door operation. Tighten
the nuts alternately and evenly until 2 stud threads
REMOVAL are visible beyond each nut.
(1) Remove the heater housing.
(2) Remove the blower motor-to-heater housing at (9) Install the glove box.
taching screws/nuts. (10) Connect the speedometer cable.
(3) Remove the blower motor from the housing. (11) Connect the heater hoses.
J H E A T I N G AND A I R CONDITIONING 24 - 45
(12) Fill and bleed the cooling system. CAUTION: Do not over tighten the attaching nuts.
The housing could become distorted causing air
FRESH AIR DOOR VACUUM MOTOR leaks and improper heater door operation. Tighten
the nuts alternately and evenly until 2 stud threads
REMOVAL are visible beyond each nut.
(1) Remove the glove box and assist handle.
(2) Disconnect the vacuum hose from the motor. (9) Install the glove box and assist handle.
(3) Remove the motor lever retaining clip. (10) Connect the speedometer cable.
(4) Remove the motor attaching nuts and remove (11) Connect the heater hoses.
the motor from the fresh air duct. (12) Fill and bleed the cooling system.
INSTALLATION
DESCRIPTION (AIR CONDITIONING)
(1) Position the motor on the fresh air duct and in
The evaporator, blower fan and motor, thermostat,
stall the motor attaching nuts.
expansion valve, capillary tube, air outlets and sys
(2) Align the motor lever with the air door lever
tem controls are located in the evaporator housing.
and install the lever retaining clip.
The evaporator housing is mounted under the instru
(3) Connect the vacuum hose to the motor.
ment panel. The compressor, condenser, receiver-
(4) Install the glove box and assist handle.
dryer and refrigerant lines are located in the engine
compartment.
FRESH AIR INTAKE DUCT
A rotary-type compressor with magnetic clutch op
REMOVAL erated drive pulley is used for all vehicles equipped
with air conditioning.
WARNING: HOT ENGINE COOLANT CAN CAUSE
SEVERE BURNS. DO NOT OPEN THE RADIATOR SIGHT GLASS
DRAIN COCK WHEN THE COOLING SYSTEM IS A sight glass is located on the top of the receiver-
HOT AND PRESSURIZED. ALLOW THE COOLANT drier (Fig. 6). The sight glass provides a visual check
TO DECREASE TO ROOM TEMPERATURE BEFORE of system refrigerant level. A continuous stream of
STARTING REPAIR OPERATIONS. bubbles will appear in the sight glass when system
(1) Drain approximately 1.9 liters (2 qts) of coolant tem is fully charged.
from the radiator. Drain the coolant into a clean con
tainer.
(2) Disconnect the heater hoses.
SIGHT
(3) Remove the nuts attaching the heater housing GLASS
studs to the dash panel from inside the engine com
partment.
(4) Disconnect the speedometer cable.
(5) Remove the glove box and assist handle.
(6) Tilt the heater housing back and pull it rear
ward and out from under the instrument panel.
(7) Disconnect the vent cables.
(8) Remove the fresh air intake grille from the
cowl. Fig. 6 Sight Glass
(9) Remove the fresh air intake duct. A/C CONTROL PANEL
INSTALLATION FAN SWITCH
(1) Install th.e fresh air intake duct. The fan switch may be serviced by removing the
(2) Install the defroster nozzle and duct. access plate located on the lower evaporator core
(3) Raise and secure the windshield. housing.
(4) Install the fresh air grille on the cowl.
(5) Install the vent cables. TEMPERATURE CONTROL THERMOSTAT
(6) Position the heater housing on the dash panel.
Be sure all the housing studs extend through the REMOVAL
dash panel. (1) Lower the evaporator housing.
(7) Install the seals on the blower motor and (2) Remove the attaching screws holding the top
heater core inlet and outlet tubes. and bottom housings together.
(8) Install the attaching nuts on the heater hous (3) Separate the housings.
ing studs. (4) Remove the thermostat.
INSTALLATION (3) Place the condenser in position and connect the

(1) When installing a replacement temperature hose fitting to the receiver-drier.
control thermostat, insert the capillary tube into the (4) Install the condenser attaching screws.
evaporator coil a minimum of 50 mm (2 inch) (Fig. (5) Connect the condenser pressure pipe fitting.
7), (6) Install the radiator and fan shroud.
(7) Fill the cooling system.
CAUTION: Handle the tube with care to avoid bends (8) Evacuate, charge and leak test the air condi
or kinks that could cause the thermostat to mal tioning system.
function.
RECEIVER-DRIER REPLACEMENT
(2) Assemble the housing and install the attaching
screws. Do not over tighten the attaching screws. REMOVAL
(3) Install the evaporator housing. (1) Discharge the system slowly to prevent loss of
EVAPORATOR COIL | 3.00 INCHES
INSULATION compressor oil.
UPPER PART O F CASE (2) Disconnect the evaporator and condenser hose
fittings from the receiver-drier.
(3) Remove the receiver-drier attaching screws. Re
move the receiver-drier.
INSTALLATION
(1) Position the receiver-drier in place. Install and
tighten the receiver-drier attaching screws.
CAPILLARY T U B E
(2) Connect the evaporator and condenser hose fit
J91 24-38® tings to the receiver-drier.
(3) Charge the system.
Fig. 7 Temperature Control Thermostat (4) Preform the leak test on the system.
A/C CONDENSER
EVAPORATOR AND HOUSING
REMOVAL
REMOVAL
WARNING: DO N O T L O O S E N T H E R A D I A T O R (1) Discharge the system. Discharge the system
DRAIN COCK W H E N T H E COOLING S Y S T E M I S slowly to prevent loss of compressor oil.
HOT AND P R E S S U R I Z E D . H O T COOLANT CAN (2) Disconnect the inlet (suction) hose.
CAUSE SERIOUS BURNS. (3) Disconnect the receiver-drier-to-evaporator
hoses.
(1) Discharge the system slowly to prevent loss of (4) Remove the hose clamps and dash grommet re
compressor oil. taining screws.
(2) Drain the radiator. Drain the coolant into a
(5) Remove the evaporator housing-to-instrument
clean container.
panel attaching screws and the housing mounting
(3) Remove the fan shroud and radiator.
bracket screw (Fig. 8).
(4) Disconnect the pressure pipe fitting from the
condenser.
EVAPORATOR H O U S I N G
(5) Remove the condenser attaching screws and tilt M O U N T I N G SCREWS
the bottom of the condenser toward the engine. Plug
all the condenser openings to prevent entry of
dirt or moisture.
(6) Working from under the vehicle, disconnect the
receiver-drier to-evaporator hose fitting from the re
ceiver-drier.
(7) Remove the condenser and receiver-drier as an
assembly.
(8) Remove the receiver-drier from the condenser, J9124-40
if necessary.
Fig. 8 Evaporator Housing
INSTALLATION (6) Lower the evaporator housing and pull the
(1) If the condenser is replaced, add 1 ounce of re hoses and hose grommet through the dash opening.
frigerant oil to the system.
(2) Attach the receiver-drier to the condenser.
J H E A T I N G A N D A I R CONDITIONING 24 - 47
The blower motor, blower motor housing, evapora (4) Mark the capillary tube location on the evapo
tor core, control switches and expansion valve can all rator tubing.
be serviced after removing the evaporator housing (5) Disconnect the inlet and outlet hose fittings,
(Fig. 9). and remove the capillary tube clamp.
(6) Disconnect and remove the expansion valve.
INSTALLATION
(1) If the evaporator is replaced, add 1 ounce of re INSTALLATION
frigerant oil to the system.
(1) Clean the evaporator tubing to provide a posi
(2) Push the hoses through the grommet openings
and install the hose grommet by pushing it toward tive metal-to-metal contact for the replacement ex
the engine compartment. pansion valve capillary tube.
(3) Install the hose grommet attaching screws. (2) Install the replacement expansion valve.
(4) Raise the evaporator housing. Install the evap (3) Clamp the capillary tube at the marked loca
orator housing-to- instrument panel attaching screws tion on the evaporator tubing.
and the evaporator housing mounting bracket screw. (4) Connect the inlet and outlet hose fittings. The
(5) Install the hose clamps. capillary tube must be securely clamped and
(6) Connect the receiver-drier hoses. have positive metal-to-metal contact with the
(7) Connect the inlet (suction) hose. evaporator tubing.
(8) Evacuate, charge and leak test the system. (5) Wrap the expansion valve, inlet hose fitting
and capillary tube with insulation.
EXPANSION (H) WALVE
(6) Install the evaporator housing.
REMOVAL (7) Evacuate, charge and leak test the system.
(1) Discharge the system slowly to prevent loss of
compressor oil. A/C BLOWER MOTOR
(2) Remove the evaporator housing. It is not necessary to discharge the system to ser
(3) Remove the insulation wrapped around the suc vice the blower motor. The evaporator housing need
tion hose fitting, expansion valve and evaporator only be lowered for access to the blower motor at
tubing. taching screws.
24 - 4 8 HEATING AND AIR CONDITIONING
1. FEED WIRE 13. D R A I N T U B E

2. BLOWER FAN 14. T E M P E R A T U R E C O N T R O L K N O B
3. BLOWER HOUSING 15. F A N C O N T R O L K N O B
4. GROMMET 16. N U T
5. HOSE 17. T H E R M O S T A T
6. CAPILLARY T U B E 18. F A N C O N T R O L S W I T C H
7. EXPANSION VALVE 19. S W I T C H H A R N E S S
8. INSULATION 20. U P P E R H O U S I N G
9. EVAPORATOR CORE 21. BRACKET
10. LOWER HOUSING 22. I N S U L A T I O N
11. LOUVER PANEL 23. B L O W E R M O T O R
12. LOUVER J9124-12
Fig. 9 Evaporative Housing and Components

HEATING AND AIR CONDITIONING 24 - 49
DESCRIPTION TORQUE DESCRIPTION TORQUE
Compressor Cylinder H e a d Heater Hose Clamps

Bolts 32 N m (24 ft. lbs.) Worm Type 3.4 N m (30 in. lbs.)
Compressor Mounting Bolts 27 N m (20 ft. lbs.) Heater Housing/Dash Panel
Compressor Oil Filter Plug . 10 N m (7 ft. lbs.) Stud Nuts. . 6 N m (55 in. lbs.)
Condenser Screws - 2.51 . 6 N m (55 in. lbs.)

Magnetic Clutch Hex Nut. 37 N m (27 ft. lbs.)
4.0L . 2 N m (20 in. lbs.)
Condenser Nuts - 4.0L . . . 3 N m (26 in. lbs.) Receiver Screws - 2.5L 3.7 N m (33 in. lbs.)
4.0L . . 7 N m (62 in. lbs.)
Discharge/Suction Hose
Fitting O-Ring T y p e . . 33 N m (24 ft. lbs.) Service Valve /Compressor
Fitting** 34 N m (25 ft. lbs.)
Evaporator /Receiver Hose Service Valve Screws

Coupling 14 N m (10 ft. lbs.) Flange Type 20 N m (15 ft. lbs.)
Expansion Valve-to- Steering Column Retaining
Evaporator Connection 24 N m (18 ft. lbs.) Nuts. 27 N m (20 ft. lbs.)
*Wet Torque - Lubricate the service valve coupling threads and O-ring with compressor oil J9224-2
EMISSION CONTROL S Y S T E M S 25 - 1
EMISSION CONTROL SYSTEMS
CONTENTS
page page
COMPONENT R E M O V A L / I N S T A L L A T I O N 8 EXHAUST EMISSION CONTROLS .. 7
EVAPORATIVE EMISSION CONTROLS 4 GENERAL INFORMATION .. 1
GENERAL INFORMATION
VEHICLE EMISSION CONTROL INFORMATION The label also contains an engine vacuum sche
(VECI) L A B E L matic. There are unique labels for vehicles built for
All vehicles are equipped with a combined VECI sale in the state of California and the country of
label. The label is located in the engine compartment Canada. Canadian labels are written in both the En
(Figs. 1 or 2). The label contains the following: glish and French languages. These labels are perma
• Engine family and displacement nently attached and cannot be removed without
• Evaporative family defacing information and destroying it.
• Emission control system schematic
VECI
• Certification application LABEL
• Engine timing specifications (if adjustable)
• Idle speeds (if adjustable)
• Spark plug and plug gap
J9325-28
Fig. 2 VECI Label Location-YJ Models
J9325-27
Fig. 1 VECI Label Location-XJ Models

25 - 2 EMISSION CONTROL SYSTEMS
The following label illustrations are used as

examples only. If there are any differences between
these illustrations and the VECI label, those shown
on the VECI label should be used.
FEDERAL VECI LABEL-TYPICAL
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CANADIAN VECI LABEL-TYPICAL
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J9325-8
J EMISSION CONTROL SYSTEMS 25 - 3
VACUUM HOSE ROUTING SCHEMATICS ences between these schematics and the Vehicle Emis
The following vacuum hose routing schematics sion Control Information (VECI) label schematics, those
are used as examples only. If there are any differ shown on the VECI label should be used.
VACUUM ROUTING SCHEMATIC—2 5L m 4 CYLINDER ENGINE
. M A P SENSOR ORIFICE
T O CLIAAATE C O N T R O L ,
CRUISE C O N T R O L ,
4x4 A X L E
( W H E N EQUIPPED)
EVAP CANISTER
T H R O T T L E BODY
T O BRAKE BOOSTER
AIR
FUEL CLEANER
PRESSURE
REGULATOR
J9325-29
VACUUM ROUTING SCHEMA TIC—4.0L 6 CYLINDER ENGINE

25 - 4 EMISSION CONTROL SYSTEMS J
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
Crankcase Ventilation System . . . . . . . . . . . . . . ... . 5 Fuel Tank Filler Tube Cap 4
Evap (Evaporation) Control System •••4 4 Pressure Relief/Rollover Valve 6
Evap Canister 4
EVAP (EVAPORATION) CONTROL SYSTEM

GENERAL INFORMATION
The function of the EVAP control system is to pre
vent the emissions of gasoline vapors from the fuel
tank into the atmosphere. When fuel evaporates in
the fuel tank, the vapors pass through vent hoses or
tubes to a carbon filled EVAP canister. They are
temporarily held in the canister until they can be
drawn into the intake manifold when the engine is
running.
The EVAP canister is a feature on all models for
the storage of fuel vapors from the fuel tank.
The hoses used in this system are specially
manufactured. If replacement becomes neces
sary, it is important to use only fuel resistant
hose. Fig. 2 EVAP Canister Location—YJ Models
CANISTER OPERATION
EVAP CANISTER The EVAP canister is equipped with a vacuum con
A sealed, maintenance free, EVAP canister is used trolled purge shutoff switch (orifice) (Figs. 1 or 2)
on all vehicles. On XJ models, the EVAP canister is that controls canister purge operation. The switch is
located in the engine compartment on the passenger open when manifold vacuum is applied to it. When
side frame rail (Fig. 1). On YJ models, the EVAP the engine is operating, the EVAP canister purge
canister is located in the engine compartment on the function draws fresh air through the top of the can
dash panel and below the brake master cylinder (Fig. ister. This causes the stored vapors to be drawn out
2). The EVAP canister is filled with granules of an of the canister and into the airstream in the air
activated carbon mixture. Fuel vapors entering the cleaner snorkel (Fig. 3).
EVAP canister are absorbed by the charcoal gran The air cleaner contains a venturi in the air
ules. cleaner cover used as a purge line vacuum source
(Fig. 3). The venturi effect increases the speed of the
intake air flowing by the slots in the venturi wall.
This creates a low pressure area around the slots.
When the purge shutoff switch is open, vapors from
the canister are drawn through slots and into the
airstream flowing through the venturi (Fig. 4). The
vapors pass through the intake manifold into the en
gine combustion chambers where they are consumed
during engine combustion.
FUEL TANK FILLER TUBE CAP

The fuel tank filler tube cap incorporates a two-
way relief valve that is closed to atmosphere during
normal operating conditions. The relief valve used in
fuel filler caps of all models is calibrated at a pres
sure of 10 kPa (1.5 psi) or a vacuum of 6 kPa (1.8 in.
Fig. 1 EVAP Canister Location—XJ Models Hg). When the pressure or vacuum is relieved, the
valve returns to the normally closed position.
EMISSION CONTROL SYSTEMS 25 - 5
F R E S H AIR
ccv
INLET
FITTING
A. PURGE INLET SLOTS H VENTURI

B. T O THROTTLE BODY I. CANISTER PURGE LINE
C. OUTER WALL J. T O FUEL TANK B114-104
D. INNER WALL K. EVAP C A N I S T E R
E. REMOTE AIR CLEANER L VACUUM S I G N A L Fig. 5 CCV System—2.5L Engine—Typical
F. INLET AIR ( M A N I F O L D VACUUM)
G. INTAKE AIR ACCELERATED M. P U R G E S H U T O F F FRESH CCV H O S E .
BY V E N T U R I AIR
INLET
J9325-11
Fig. 3 EVAP System—Typical

MAP
AIR CLEANER
SENSOR
COVER
O-RINGS
J9114-105
Fig. 6 CCV System—4.0L Engine—Typical

fixed orifice of a calibrated size. It meters the
amount of crankcase vapors drawn out of the engine.
PURGE On 2.5L engines, a fitting on drivers side of cylin
INLET der head (valve) cover contains the metered orifice. It
SLOTS
T O CANISTER is connected to manifold vacuum.
A fresh air supply hose from the air cleaner is con
nected to front of cylinder head cover on 4.0L en
J8925-1
gines. It is connected to rear of cover on 2.5L
Fig. 4 Air Cleaner Venturi— Typical engines.
When the engine is operating, fresh air enters the
CAUTION: T h e fuel filler cap must be removed prior engine and mixes with crankcase vapors. Manifold
to disconnecting any fuel system component.
vacuum draws the vapor/air mixture through the
fixed orifice and into the intake manifold. The vapors
CRANKCASE V E N T I L A T I O N S Y S T E M are then consumed during combustion.
All 2.5L 4 cylinder and 4.0L 6 cylinder engines are
equipped with a Crankcase Ventilation (CCV) system
(Figs. 5 or 6). The CCV system performs the same
function as a conventional PCV system, but does not
use a vacuum controlled valve.
On 4.0L engines, a molded vacuum tube connects
manifold vacuum to top of cylinder head (valve)
cover at dash panel end. The vacuum tube contains a
25 - 6 EMISSION CONTROL S Y S T E M S
J
PLUNGER
SPRING
Fig. 8 Pressure Relief/Rollover Valve Operation

Fig. 7 Pressure Relief/Rollover Valve
Location—Typical and also prevent fuel flow through the fuel tank vent
hoses in the event of an accidental vehicle rollover.
P R E S S U R E R E L I E F / R O L L O V E R VALVE The valve incorporates a pressure relief mechanism
All vehicles are equipped with a combination fuel (Fig. 8) that releases fuel tank pressure when the
tank pressure relief and rollover valve (Fig. 7). This pressure increases above the calibrated sealing
dual function valve will relieve fuel tank pressure value. Refer to the Fuel Tank section of Group 14,
Fuel Systems for removal and installation proce
dures.
J EMISSION CONTROL SYSTEMS 25 - 7
EXHAUST EMISSION CONTROLS

AIR CLEANER
The air cleaner used on all models (Figs. 1 or 2) is
open to ambient air. The blend air door and vacuum
motor that was used on engines of previous model
years to supply heated air, is no longer used. The air
cleaner housing assembly contains the engine air fil
ter.
The Powertrain Control Module (PCM) monitors
air temperature in the intake manifold through the
Intake Manifold Air Temperature sensor. The PCM
adjusts injector pulse width and ignition timing to
compensate for intake air temperature. Refer to Pow
ertrain Control Module (PCM) in Group 14, Fuel Sys
tem for more information.
Refer to the Component Removal/Installation sec
tion of this group for removal and installation proce
dures.
OXYGEN ( 0 ) S E N S O R
2
For description, operation, diagnosis and removal/

installation procedures of the 0 sensor, refer to
2
Group 14, Fuel Systems.
Fig. 1 Air Cleaner—XJ Models—Typical
Fig. 2 Air Cleaner— YJ Models—Typical

21 - 8 EMISSION CONTROL SYSTEMS J
COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Air Cleaner Housing 8 Fuel Tank Filler Tube Cap 9
Air Filter 9 Oxygen ( 0 ) Sensor
2 ....................... 9
Coolant Temperature Sensor 9 Powertrain Control Module (PCM) 9
Evap Canister 9 Pressure Relief/Rollover Valve 9
AIR CLEANER HOUSING
REMOVAL
(1) Unlock clean air hose clamp (Figs. 3 or 4) at
air cleaner cover. To unlock the clamp, attach adjust
able pliers to clamp and rotate pliers as shown in fig
ure 3. Remove clean air hose at cover.
(2) Disconnect vacuum lines at air cleaner hous
ing.
(3) YJ Models: Release the three over-center type
clamps securing the housing to the housing bracket.
XJ Models: Remove the housing cover and remove
air filter. Remove two bolts and one nut.
Fig. 4 Air Cleaner— YJ Models—Typical

CLAMP ADJUSTABLE PLIERS
J9314-136
Fig. 5 Clamp Removal

INSTALLATION
Fig. 3 Air Cleaner—XJ Models—Typical (1) Position air cleaner housing to body and ambi
ent air inlet.
(4) Release the air cleaner housing from the ambi
(2) YJ Models: Lock the three over-center type
ent air inlet and remove housing from vehicle. clamps securing the housing to the housing bracket.
XJ Models: Install two bolts and one nut to housing.
J EMISSION CONTROL S Y S T E M S 25 - 9
Install air filter and cover.

(3) Install vacuum lines to housing.
(4) Install clean air hose and clamp to cover. Com
press the clamp snugly with adjustable pliers as
shown in figure 6.
CLAMP ADJUSTABLE PLIERS
Fig. 6 Clamp Installation

AIR FILTER
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.
(2) Lift the cover up and position to the side.
(3) Remove air filter.
(4) Clean the inside of air cleaner housing before
installing new filter.
(5) Reverse the preceding operation for installa
tion. Be sure the air cleaner cover is properly seated Fig. 8 EVAP Canister— YJ Models
to air cleaner housing. Reverse the procedure for installation.
COOLANT TEMPERATURE SENSOR F U E L T A N K F I L L E R T U B E CAP
For description, operation, diagnosis and removal/ If replacement of the fuel filler tube cap is neces
installation procedures of the engine coolant temper sary, it must be replaced with an identical cap to be
ature sensor, refer to Group 14, Fuel Systems. sure of correct system operation.
EVAP CANISTER OXYGEN ( 0 ) S E N S O R
2
On XJ models, the EVAP canister is located in the For description, operation, diagnosis and removal/
engine compartment on the passenger side frame rail installation procedures of the 0 sensor, refer to
2
(Fig. 7). On YJ models, the EVAP canister is located Group 14, Fuel Systems.
in the engine compartment on the dash panel and be
low the brake master cylinder (Fig. 8). P O W E R T R A I N C O N T R O L M O D U L E (PCM)
For removal and installation procedures, refer to
REMOVAL Group 14, Fuel Systems.
(1) Disconnect the vacuum lines at the EVAP can
ister. Note location of lines before removal. PRESSURE RELIEF/ROLLOVER VALVE
(2) Remove canister retaining strap bolt. For removal and installation procedures, refer to
(3) Remove canister from vehicle. the Fuel Tank section of Group 14, Fuel Systems.
COMPONENT A N D S Y S T E M INDEX
Name Group-page Name Group-page

AUDIO SYSTEMS 8F-1 GAUGE PACKAGE SERVICE PROCEDURES 8E-24
GENERAL INFORMATION 8F-1 GENERAL INFORMATION 8E-1
RADIO ANTENNA 8F-7 GENERAL INFORMATION 8E-14
XJ SERVICE PROCEDURES 8F-4 INSTRUMENT CLUSTER DIAGNOSIS 8E-3
YJ SERVICE PROCEDURES 8F-6 INSTRUMENT CLUSTER DIAGNOSIS 8E-14
BATTERY/STARTER/GENERATOR SERVICE 8B-1 INSTRUMENT CLUSTER SERVICE PROCEDURES . . . 8E-5
BATTERY SERVICE PROCEDURES 8B-1 INSTRUMENT CLUSTER SERVICE PROCEDURES . . 8E-17
ENGINE STARTER MOTOR SERVICE PROCEDURES . 8B-4 SPECIFICATIONS 8E-13
GENERATOR SERVICE PROCEDURES 8B-7 SPECIFICATIONS 8E-27
SPECIFICATIONS 8B-10 LAMPS 8L-1
BATTERY/STARTING/CHARGING SYSTEMS EXTERIOR LAMPS 8L-1
DIAGNOSTICS 8A-1 INTERIOR LAMPS 8L-17
BATTERY TEST PROCEDURES 8A-2 SPECIFICATIONS 8L-21
ENGINE STARTER MOTOR TEST PROCEDURES POWER DOOR LOCKS 8P-1
ON VEHICLE 8A-8 KEYLESS ENTRY 8P-5
GENERATOR TEST PROCEDURES ON VEHICLE . . . 8A-15 POWER LOCKS 8P-1
IGNITION OFF DRAW (IOD) 8A-14 POWER MIRRORS 8T-1
CHIME/BUZZER WARNING SYSTEMS 8U-1 POWER SEATS 8R-1
GENERAL 8U-1 POWER WINDOWS 8S-1
IGNITION KEY WARNING SWITCH REPLACEMENT. . 8U-4 REAR WINDOW DEFOGGER 8N-1
OPERATION/DIAGNOSIS 8U-1 GENERAL 8N-1
EMISSION CONTROL SYSTEMS 25-1 XJ 8N-4
COMPONENT REMOVAL/INSTALLATION 25-8 YJ 8N-4
EVAPORATIVE EMISSION CONTROLS 25-4 SPLICE LOCATIONS 8-43
EXHAUST EMISSION CONTROLS 25-7 WIRING DIAGRAMS YJ 8-57
GENERAL INFORMATION 25-1 XJ SPLICE LOCATIONS 8-49
HEATING AND AIR CONDITIONING 24-1 YJ SPLICE LOCATIONS 8-43
CLIMATE CONTROL S Y S T E M - X J VEHICLES 24-26 TURN SIGNALS AND HAZARD WARNING FLASHER . . . 8J-1
CLIMATE CONTROL S Y S T E M - Y J VEHICLES 24-41 HAZARD L A M P S - X J 8J-1
COMPRESSOR OVERHAUL 24-17 HAZARD L A M P S - Y J 8J-2
GENERAL INFORMATION 24-1 TURN SIGNALS-XJ 8J-1
SERVICE DIAGNOSIS-ELECTRICAL 24-14 TURN SIGNALS-YJ 8J-2
SERVICE DIAGNOSIS-MECHANICAL 24-8 TURN/HAZARD SWITCH REPLACEMENT -
TORQUE SPECIFICATIONS 24-49 ALL MODELS 8J-3
HORNS 8G-1 VEHICLE SPEED CONTROL SYSTEM 8H-1
GENERAL INFORMATION 8G-1 SERVICE PROCEDURES 8H-8
HORN SWITCH (HORN PAD) REPLACEMENT 8G-3 TEST PROCEDURES 8H-5
TORQUE SPECIFICATIONS 8G-4 WINDSHIELD WIPERS 8K-1
XJ 8G-1 WIPER CONTROL SWITCH REPLACEMENT 8K-14
YJ 8G-3 WIPER SWITCH TESTING 8K-18
IGNITION SYSTEMS 8D-1 XJ 8K-1
COMPONENT IDENTIFICATION/SYSTEM OPERATION. 8D-1 YJ 8K-7
COMPONENT REMOVAL/INSTALLATION 8D-19 WIRING AND COMPONENT IDENTIFICATION 8W-13
DIAGNOSTICS/SERVICE PROCEDURES 8D-8 XJ 8W-25
IGNITION SWITCH-ALL MODELS 8D-29 YJ 8W-13
SPECIFICATIONS 8D-32 WIRING DIAGRAMS XJ 8W-131
INSTRUMENT PANEL AND GAUGES 8E-1 WIRING DIAGRAMS 8W-1
GAUGE PACKAGE DIAGNOSIS 8E-22 FUSE CHARTS AND RELAY BANKS 8W-8
GAUGE PACKAGE GENERAL INFORMATION 8E-22 GENERAL INFORMATION 8W-1
Fold Here
Place
Stamp
Here
Chrysler Corporation
Service Publications
CIMS 424-81-55
25999 Lawrence Ave.
Center Line, Ml 48015
Fold Here
SERVICE
MANUAL
Jeep
CHRYSLER
CORPORATION
ENGINE-CHASSIS-BODY
SERVICE MANUAL
1993
CHEROKEE
WRANGLER (YJ)
To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.
^CHRYSLER
^CORPORATION
SERVICE & PARTS DIVISION
NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY A N Y MEANS, ELECTRONIC, ME
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga
tions upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1992 Chrysler Corporation 20M0992

1993 SERVICE MANUAL COMMENTS
Chrysler Corporation welcomes your feedback on this service manual. Your comments will help
improve the quality of future manuals. Please describe your suggestions, any errors, or other
comments below. In some cases, it may be helpful to send a copy of the service manual page
marked with your comments.
What features do you find most useful?
What errors have you found? Please Include page number.
What topics are hard to locate, confusing, or not covered completely?
What comments or suggestions do you have?
Your N a m e : -— —-——— ~ _ Dealership:

Address: -——— —— ——^ ^ —
Manual N a m e and Model Year: -— —————
Note: All comments become the property of Chrysler Corporation.

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re
placing fasteners, always use the same type (part number) fastener as removed.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
T h e Component and System Index of this manual identifies the correct group for the component or system
to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the
form to provide Chrysler Corporation with your comments and suggestions.
T o assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group, The first page of the group has
a contents section that lists major topics within the group.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
Information describing the operation and use of standard and optional equipment is included in the Own
er's Manual provided with the vehicle.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993 Cal
ifornia Air Research Board (CARB) requirements.
i
Navigation: Click on "Index" below, or use the Bookmarks to the left.
GROUP TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Front Suspension and Axle
3 Rear Suspension and Axles
f§ Brakes
@ Clutch
7 Cooling System
€| Engines
"f Exhaust System and Intake Manifold
1 3 Frame and Bumpers
^ 4 Fuel System
1 6 Propeller Shafts
1 9 Steering
2 *! T r a n s m i s s i o n s and Transfer Cases
22 Wheels and T i r e s
B
23 ° d y Components
Component and System Index
Service Manual Comment F o r m s (Rear of Manual)

/
INTRODUCTION 1
INTRODUCTION
CONTENTS
page page
DESIGNATIONS, LABELS/PLATES, CODES AND SPECIFICATIONS 8

DIMENSIONS 1
DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS
INDEX
page page
Engine and Transmission/Transfer Case Vehicle Designations 1
Identification 3 Vehicle Dimension Data 4
International Vehicle Control and Display Symbols . 4 Vehicle Identification Number (VIN) Plate 2
Major Component Identification . 3 Vehicle Load Data 4
Tire Inflation Pressure Label 3 Vehicle Safety Certification Label 1
Vehicle Code Plate 2
VEHICLE DESIGNATIONS
The Vehicle Designation Codes chart lists the vehi
cle description(s) and the corresponding vehicle des
ignation code for each type of Jeep® vehicle (Figs. 1 ,
2, and 3). The vehicle designation codes are different
from the Vehicle Identification Number (VIN) or
body-type/style codes.
VEHICLE DESIGNATION CODES
VEHICLE D E S C R I P T I O N CODE
CHEROKEE - 2DR/4WD
CHEROKEE - 4DR/4WD
Fig. 1 YJ-Wrangler Multi-Purpose Vehicle (With
CHEROKEE - 2DR/2WD XJ Hard Top)
VEHICLE SAFETY CERTIFICATION LABEL
CHEROKEE - 4DR/2WD A vehicle safety certification label (Fig. 4) is at
tached to each Jeep® vehiclee. The label also lists
the:
WRANGLER - 4WD YJ
• gross vehicle weight rating (GVWR) and the gross
J931N-15 front and rear axle weight ratings (GAWR's) based
on a minimum tire rim size and a maximum cold tire
inflation pressure;
• month and year of vehicle manufacture;
• vehicle identification number (VIN);
• type of vehicle and
• month, day and hour (MDH) of final assembly.
The label is located on the driver's side door edge.
2 INTRODUCTION J
M F H RY CHRYSLER DATE OF M F R GVWR

MFD B Y CORPORATION
GAWR FRONT WITH TIRES R I M S AT PSI COLD
GAWR REAR WITH TIRES R I M S AT PSI COLD
T H I S VEHICLE C O N F O R M S TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

S T A N D A R D S I N E F F E C T O N T H E DATE O F M A N U F A C T U R E S H O W N A B O V E .
TYPE: SINGLE DUAL
BAR CODE
J91IN-13
MDH: VEHICLE MADE I N
4648503 J91IN-25
Fig. 4 Vehicle Safety Certification Label
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The vehicle identification number (VIN) plate is at
tached to the top left side of the instrument panel at
the base of the windshield. Each VIN contains 17 al
pha-numerical characters. Refer to the decoding
chart to determine the actual identification of a
Jeep® vehicle.
V E H I C L E CODE P L A T E
A metal vehicle code plate is attached to the left
(driver) side of the dash panel in the engine compart
ment (Fig. 5). There can be a maximum of seven
rows of vehicle information imprinted on the plate.
J9223-15 The information should be read from left to right,

VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country Vehicle Line Engine Sequential

Type P = 2.5 Liter 1-4 S e r i a l Number
1 - U.S. J = Cherokee - 4 W D S = 4.0 Liter 1-6 S i x Digit Numbers
4 - MPV T = Cherokee - 2 W D
6 = Incomplete Y = Wrangler - 4 W D
J 4 F J 000001
L
Make
1
GVWR Series Check Digit
I
1993
Model
\
Plant Location
J = Jeep E = 3001-4000 1 = S (YJ) Number or Letter L = Toledo #1
F = 4001-5000 2 = Base Year P « Toledo #2
G = 5001-6000 4 = Sahara
5 <= Laredo Body
6 = Renegade 7 = 2-Dr. Wagon
8 = 4-Dr. Wagon
9 - 2-Dr. Open Body
J931N-14
J INTRODUCTION 3
starting with line 1 at the bottom of the plate up The last nine positions of row 7 will contain a
through line 7 (as applicable) at the top of the code 2-digit code, when applicable, and a 6-digit gateline
plate. serial number (same as the last 6 numbers of the
PRIMARY SECONDARY VINYL ROOF
VIN).
PAINT PAINT CODE The last code imprinted on a vehicle code plate will
I be followed by the imprinted word END. When two
vehicle code plates are required, the last available
VEHICLE
spaces on the first plate will be imprinted with the
VEHICLE MODEL letters CTD (for continued).
ORDER- -NUMBER
NUMBER
When a second vehicle code plate is necessary, the
(3) XXX > KXXXX) X XXX xxxxxx ENGINE first four spaces on each row will not be used because
PAINT - -CODE of the plate overlap.
PROCEDURE (2) XXX )OCXX XXXX XXXX XXX
-INTERIOR
0) XXX X XXXXXXXXXXXXXXXXX TRIM CODE ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
T R A N S M I S S I O N I VEHICLE IDENTIFICATION When required, refer to Group 9—Engines for all
CODE J NUMBER
MARKET U-C-B-M
engine identification data. Refer to Group 21—Trans
CODE °0»N-3 missions for all transmission/transfer case identifica
tion data.
Fig. 5 Vehicle Code Plate
Refer to the decoding chart to decode lines 1 up MAJOR COMPONENT IDENTIFICATION
through 3. When required, refer to the applicable service in
formation group for major component identification
VEHICLE CODE DECODING data.
Line f l Digit 1-3 Transmission Sales Code T I R E INFLATION P R E S S U R E L A B E L

Digit 4 Open Space The tire inflation pressures label is located on the
Digit 5 Market Code - U-C-B-M
Digit 6 Open Space glove box door inside panel (Fig. 6). The tires should
Digit 7-23 Vehicle Identification No. also be inspected for visible wear. Also, inspect the
Line # 2 Digit 1-3 Paint Procedure tires for cracks, bulges and other road hazard dam
Digit 4 Open Space age. Refer to Group 22—Tires And Wheels.
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit 20-22 Engine Sales Code
Digit 23 Open Space
Line # 3 Digit 1 - 1 2 Vehicle Order Number

Digit 1 3 Open Space
Digit 1 4 - 1 6 Vinyl Roof Code (Door Combo
Code - Pillette)
Digit 1 7 Open Space
Digit 1 8 - 2 3 Model
J901N-20
Lines 4 through 7 (if used) on the vehicle code

plate are imprinted on the plate (in sequence) accord
ing to the following:
• 3-character sales code,
• 3-digit numerical code, and
• 6-digit SEC code.
If there is not enough space left in the row for all
of the 6-digit SEC code (if used):
• the unused space will remain blank, and J891N-3
• the code will be listed in the next row.
Fig. 6 Tire Inflation Pressures Label—Typical
4 INTRODUCTION
VEHICLE DIMENSION DATA # the cargo weight, and

The vehicle dimension data charts list the exterior • the passenger weight for each Jeep® type/body
and interior dimensions for each type of Jeep® vehi style.
cle.
INTERNATIONAL VEHICLE CONTROL AND D I S P L A Y
V E H I C L E LOAD D A T A SYMBOLS
The Vehicle Load Data chart lists the following in Most of the graphic symbols illustrated in the fol
formation:
lowing chart are used to identify various instrument
• the gross vehicle weight rating (GVWR),
• the gross axle weight ratings (GAWR), controls and displays.
VEHICLE EXTERIOR DIMENSION DATA
TRACK OVERALL
MODEL NAME MODEL BASE FRONT REAR LENGTH WIDTH HEIGHT
cm/in cm/In cm/in

2 DR-2WD 101.4 58.0 58.0 165.3 70.5 63.4
7-in Wheels 257.6 144.8 420.0 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4

4 DR-2WD
7-in Wheels
101.4
257.6
101.4
57.0
147.3
58.0
57.0
147.3
58.0
165.3
420.0
165.3
70.5
179.1
70.5
63.4
161.0
63.4
I
Cherokee
2 DR-4WD
6-in Wheels
7-in Wheels
XJ 257.6
101.4
257.6
101.4
144.8
57.0
147.3
58.0
144.8
57.0
147.3
58.0
420.0
165.3
420.0
165.3
179.1
70.5
179.1
70.5
161.0
63.4
161.0
63.4
I
3
Cherokee 6-in Wheels XJ 257.6 144.8 144.8 420.0 179.1 161.0 S
4 DR-4WD 101.4 57.0 57.0 165.3 70.5 63.4
7-in Wheels 257.6 147.3 147.3 420.0 179.1 161.0 5
101.4 58.0 58.0 165.3 70.5 63.4
Wrangler YJ 237.2 147.3 147.3 387.6 167.7 176.5 I

2 DR-4WD 93.4 58.0 58.0 152.6 66.0 69.5
§
VEHICLE INTERIOR DIMENSION DATA
ss
HEAD LEG SHOULDER HIP
VEHICLE MODEL FRONT REAR FRONT REAR FRONT REAR FRONT REAR
cm/in cm/in cm/In cm/in
Cherokee XJ 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0

38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5
Wrangler
(Hardtop)
YJ 102.1
40.2
102.9
40.5
100.1
39.4
88.9
35.0
134.8
53.1
143.0
56.3
134.8
53.1
91.4
36.0
5
o
J931N-16
en
6 INTRODUCTION
J
VEHICLE LOAD DATA
4
BODY' WHEEL/ PASSENGER CARGO 3
GAWR 4
GAWR
VEHICLE STYLE TIRE GVWR" W E I G H T (MAX) W E I G H T (MAX) FRONT REAR
XJ 15x6 2606
2WD 72 P195/75R 4550 750 400 2500
XJ 15x6
2WD 74 P19575R 4600 750 400 2500 2606
XJ 15x6
4WD 72 P195/75R 4850 750 400 2500 2606
XJ 15x6
4WD 74 P195/75R 4900 750 400 2500 2606
72
XJ W/TRAILER 15x7
2WD P215/75R 4550 750 400 2500 2700
TOW PACKAGE
74
XJ W/TRAILER 15x7
2WD P215/75R 4600 750 400 2500 2700
TOW PACKAGE
XJ 72
W/TRAILER 15x7
4WD P215/75R 4850 750 400 2500 2700
TOW PACKAGE
74
XJ W/TRAILER 15x7
4WD P215/75R 4900 750 400 2500 2700
TOW PACKAGE
XJ 15x7
4WD BRIARWOOD P215/75R 4900 750 400 2500 2700
YJ ALL EXCEPT
RENEGADE N/A N/A 300 200 N/A N/A
All Weights Listed In Pounds. 2

72 = 2-Door Body 3
Gross Vehicle Weight Rating
74 = 4-Door Body 4
For MJ Vehicles, includes options
Gross Axle Weight Rating
J INTRODUCTION 7
VEHICLE CONTROL AND DISPLAY SYMBOLS
ID
HEADUGHTS,
PARKING UGHTS,
A i i
WINDSHIELD
%
HIGH BEAM FOG LIGHTS PANEL UGHTS T U R N SIGNAL HAZARD WARNING WASHER
WINDSHIELD
WIPER
WINDSHIELD WIPER
AND WASHER
<W
WINDSCREEN
DEMISTING
AND DEFROSTING
*
VENTILATING FAN
WjTM
REAR W I N D O W
DEFOGGER
GP
REAR W I N D O W
WIPER
CD •
REAR W I N D O W
m {•fir
ENGINE COOLANT BATTERY CHARGING

WASHER FUEL TEMPERATURE CONDITION ENGINE OIL SEAT BELT
© (®) *-* k?
n i
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN LIGHTER
93IN-9
8 INTRODUCTION
J
SPECIFICATIONS
SPECIFICATION NOTATIONS Various sizes of (Torx) head fasteners are used
All torque specifications listed in this service man as attaching hardware for numerous compo
ual are in both metric system and SAE/English sys nents in Jeep® vehicles.
tem.
BOLT THREAD AND GRADE/CLASS
WARNING: THE USE OF INCORRECT ATTACHING IDENTIFICATION
HARDWARE CAN RESULT IN COMPONENT DAM
AGE AND/OR PERSONAL INJURY. THREAD IDENTIFICATION
SAE and metric bolt/nut threads are different. The
During all procedures, it is important to retain the difference is described in the Thread Notation chart.
original attaching hardware. If the hardware is not
reusable, replace new hardware with equivalent GRADE/CLASS IDENTIFICATION
specifications. The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
METRIC SYSTEM NOTATION the bolt strength. The grade identification is deter
The following conversion chart will assist in con
mined by the line marks on the top of each bolt head
verting SAE/English units to equivalent metric
(Fig. 7). The actual bolt strength grade corresponds
units.
to the number of line marks plus 2. For example:
TORQUE SPECIFICATIONS • a grade 2 bolt has no line marks on top of the bolt
head;
TORQUE CHARTS • a grade 5 bolt has 3 line marks on top of the bolt
If applicable, torque chart(s) for screws, bolts and head;
nuts is/are provided at the end of each service infor • a grade 7 bolt has 5 line marks on top of the bolt
mation group. Refer to the Standard Torque Specifi head; and
cations chart and the bolt grade/class identification • a grade 8 bolt has 6 line marks on top of the bolt
illustrations (Figs. 7 and 8). head.
It is important to be aware that the torque values The most commonly used metric bolt strength
listed in the chart are based on clean and dry bolt classes are 9.8 and 12.9. The metric strength class
threads. Reduce the applicable listed torque value by
identification number is imprinted on the head of the
10 percent when the bolt threads are lubricated with
bolt (Fig. 8). The higher the class number, the
engine oil and by 20 percent if new, plated bolts are
greater the bolt strength. Some metric-dimension
being tightened.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Got

in-lbs x 0.11298 = Newton-Meters (N»m) x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (N«m) N-m x 0.7376 ft-lbs
Inches H g (60°F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 Inches H g

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 psi
Inches x 25.4 Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 = Meters (M) M x 3.281 Feet
Yards x 0.9144 Meters (MJ M x 1.0936 Yards
Miles x 1.6093 Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 mph

Feet/Sec. x 0.3048 = Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 Meters/Sec. (M/S) M/S x 2.237 = mph
COMMON M E T R I C E Q U I V A L E N T S
1 Inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1 . 6 Kilometers
J91IN-1
J INTRODUCTION 9
STANDARD TORQUE VALUES

SAE CLASSIFICATION
BOLT TORQUE GRADES GRADE 8

GRADE 5 GRADES
BOLT
Ntn ft-lbs N-m ft-lbs
SIZE
1/4-20 11
(In-lbs)
(95) 14
(iit-lbs)
(125)
MARKINGS F O U N D
O N T O P O F BOLT
H E A D INDICATE
(<T>
1/4-28 11 (95) 17 (150)
GRADE
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25 120° 60°
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 110
9/16-12 142 105 183 135
9/16-18 156 115 203 150 ^ ^ R > ^ ^
5/8-11 203 150 264 195 (SAE) B O L T S — I D E N T I F I C A T I O N M A R K S C O R R E S P O N D
5/8-18 217 160 285 210 T O BOLT STRENGTH—INCREASING NUMBERS
3/4-16 237 175 305 225 R E P R E S E N T INCREASING S T R E N G T H .
J89IN-11
J89IN-9
Fig. 7 SAE Bolt Grade Identification
THREAD NOT A TION—SAE AND METRIC
INCH METRIC
5/16-18 M8 X 1.25
THREAD NUMBER THREAD DISTANCE

MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER I N T H R E A D S I N METRIC B O L T S - I D E N T I F I C A T I O N CLASS N U M B E R S
IN INCHES PER INCH MILLIMETERS MILLIMETERS C O R R E S P O N D T O B O L T S T R E N G T H — INCREASING N U M B E R S
R E P R E S E N T INCREASING S T R E N G T H . IOOIKI I Q
PR606B
Fig. 8 Metric Bolt Class Identification
nuts are also imprinted with a single-digit strength
class identification number on the nut face.
10 INTRODUCTION J
TORQUE CONVERSION
in-lbs to N*m N«m to in-lbs

i n - lb N«m in-lb N«m in-lb N*m in-lb N»m in-lb N®m in-lb N«m in-lb N*m in-lb N»m in-lb N»m
2 .2 1:7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2

.2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032
4 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4
.4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292
6 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
.6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552
8 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8
.9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811
1 8.8511 5 44.2556 9 79.6601 13 115.0646 17
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071
12 1.2 10.6213 5.2 46.0258 9.2 81.43)3 13.2 116.8348 17.2
1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331
14 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4
1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590
16 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6
1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850
18 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8
2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110
2 17.7022 6 53.1067 10 88.5112 14 123.9157 18
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369
2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629
2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19
24 2.7116 64 104 11.7502 144 16.2696 184 20.7889
26 2.9376
7.2m
7.4569 11.9762 146 16.4955 186 21.0148 2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5
28 3.1635
66
68
\Q6
7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20
3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668
3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927
3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187
3.6 31.8640 7.6 67.2685 11.6 102.673) 15.6 138.0775 23
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447
3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706
4 35.4045 8 70.8090 12 106.2135 16 141.6180 25
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966
ft-lbs to N*m N®m to ft-lbs

ft-lb N®m ft-lb N»m ft-lb N«m ft-lb N®m ft-lb N®m N*m ft-lb N»m ft-lb N©m ft-lb N«m ft-lb N»m ft-lb
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.40)1
3 4.0675 23 31.1838 43 58.3)02 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.53% 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806
11 14.9140 31 42.03)4 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6m 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7923 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 57.5298 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562
in. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .mm .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 mm .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 m m .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .033)7
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .02598 .86 .03386
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.356 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .3) .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .03433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .03569 .37 .01457 .57 .02244 .77 .03)32 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 .03)71 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 .99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
J LUBRICATION AND MAINTENANCE 0-1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY COMPONENTS .36 ENGINE MAINTENANCE 13

DRIVETRAIN 28 G E N E R A L INFORMATION 1
GENERAL INFORMATION
INDEX
page page
Classification of Lubricants 2 Recommended Lubricant and Replacement Parts . 3
Components Requiring No Lubrication . 3 Routine Service 2
Fuel Requirements 2 Starting Assistance ("Jump" Starting) .......... 3
Introduction 1 Vehicle Towing Recommendations ............ 7
INTRODUCTION • commercial service.

Jeep® lubrication and maintenance is divided into To service a Jeep® vehicle for a severe driving con
required and recommended service tasks. dition, change all the lubricating fluids and lubri
The recommendations and procedures listed in this cate:
group are intended for Jeep® Dealer Service Person • the body components,
nel. • all the driveline coupling joints, and
Because conditions vary, it is necessary to schedule • the steering linkage
service tasks according to a time interval as well as more often than for a normal driving condition to
a distance interval. prevent excessive wear of the components.
It is the owner's responsibility to have vehicle ser
viced. Owner is to pay for labor and necessary parts. D U S T Y AREAS
Additional lubrication and maintenance informa Driving in an area with dust-filled air increases
tion is listed in the Owner's Manual, which is in the risk of particles entering the engine and crank
cluded with the vehicle. case. With this type of severe driving condition, at
tention should be given to the engine and crankcase
SEVERE DRIVING CONDITIONS components.
When a vehicle is subjected to a severe driving con
dition, time between recommended maintenance OFF-ROAD (4WD) OPERATION
should be decreased. After completion of off-road (4WD) operation, the
Refer to Engine Maintenance for the engine oil and underside of the vehicle should be thoroughly in
filter maintenance interval when involved with a se spected. Examine threaded fasteners for looseness.
vere driving condition.
A severe driving condition is defined as either: HARSH SURFACE ENVIRONMENTS
• frequent short trip driving less than 24 km (15 After vehicle operation in a harsh surface environ
miles); ment, the following components should be inspected
• frequent driving in a "dusty" environment; and cleaned as soon as possible:
• trailer towing; • brake drums,
• extensive engine idling;
• brake linings,
• sustained high-speed operation;
• front wheel bearings (2WD vehicles only), and
• desert operation;
• axle coupling joints.
• frequent starting and stopping;
• cold-climate operation; This will prevent wear and/or unpredictable brake
• off-road driving; or action.
0 - 2 L U B R I C A T I O N AND MAINTENANCE
J
ROUTINE SERVICE
The following routine vehicle service is highly rec
ommended on a monthly basis.
TIRES—-Inspect the tires for unusual wear/damage UNLEADED
and determine if the inflation pressure is acceptable FUEL O N L Y
for the vehicle load.
BATTERY—Inspect and clean the terminals.
Tighten the terminals, if necessary. Determine the
electrolyte level and, if necessary, add distilled wa
ter.
FLUIDS—Determine if the coolant, brake fluid,
power steering, automatic transmission, and clutch
UNLEADED
fluid level are acceptable. Add fluid, if necessary. FUEL ONLY
LIGHTS/ELECTRICAL—Test all the electrically
operated systems in the vehicle for proper operation.
It is also recommended that the engine oil
level and the windshield washer fluid level be
determined (and corrected) during each fuel fill-
up.
Fig. 2 Unleaded Fuel Only Reminder—Fuel Filler
Door
FUEL REQUIREMENTS
All Jeep® engines require the use of unleaded gas CLASSIFICATION OF LUBRICANTS
oline. In addition, the fuel must have a minimum oc Lubricating fluids and chassis component lubri
tane rating of 87. cants are classified and graded according to stan
dards recommended by the:
CAUTION: U N L E A D E D F U E L O N L Y must be used in • Society of Automotive Engineers (SAE),
vehicles equipped with a catalyst emission control • American Petroleum Institute (API), and
system. All vehicles have reminders printed on the • National Lubricating Grease Institute (NLGI).
instrument panel (Fig. 1) and on the fuel filler door
(Fig. 2). Vehicles also have fuel filler tubes that are ENGINE OIL
designed to accept only the small-diameter un
leaded gasoline nozzles. It i s illegal to defeat the SAE VISCOSITY GRADE
design of an unleaded fuel filler tube. An SAE viscosity grade is used to specify viscosity
of engine oil. SAE 30 specifies a single viscosity en
gine oil. Engine oils also have multiple viscosities
(Fig. 3).
OIL
QUALITY
SAE
YJ V E H I C L E S VISCOSITY
GRADE
MJ/XJ
VEHICLES
FUEL
ECONOMY
NOTATION J9100-4
J9200-54
Fig. 1 Unleaded Fuel Only Reminders—Fuel Gauge Fig. 3 SAE Oil Viscosity Grade & API Service Grade
The viscosity grade of an oil is an indicator of its
thickness or flow capability. The lower the number,
the better the flow. The second viscosity grade num-
J LUBRICATION AND MAINTENANCE 0 -3
ber (without a W suffix) is the warm/hot-temperature RECOMMENDED LUBRICANT AND REPLACEMENT

viscosity. The viscosity increases with engine temper PARTS
ature. With a single viscosity grade.the oil viscosity Jeep® vehicles are engineered to provide many
is valid only for one narrow temperature range. years of dependable operation. When necessary, MO-
Above that temperature range the viscosity will de P A R brand lubricants and genuine replacement
crease, and below that range the viscosity will in parts are highly recommended.
crease.
An engine oil with an SAE 5W-30 viscosity grade COMPONENTS R E Q U I R I N G NO L U B R I C A T I O N
provides good flow capability for fast cold-weather There are many components that should not be lu
engine start-ups. The viscosity will then increase bricated. The components that should not be lubri
with engine temperature to provide good high-tem cated are:
perature engine lubrication. • air pumps;
• generator bearings;
API SERVICE GRADE • drive belts;
The API Service Grade specifies the type of engine/ • drive belt idler pulleys;
operating conditions for which the oil is intended. • rubber bushings;
The API Service Grade specifications also apply to • starter motor bearings;
"energy conserving" engine oils (Fig. 3). • suspension strut bearings;
For maximum protection, use API Service Grade • throttle control cables;
SG, SG/CD or SG/CE engine oil in Jeep® engines. • throttle linkage ball joints; and
• water pump bearings.
GEAR LUBRICANTS
A dual SAE viscosity grade is also used to specify STARTING ASSISTANCE ("JUMP" STARTING)
the viscosity of multipurpose gear lubricants.
The API lubrication quality grade designation WARNING: DO NOT ATTEMPT TO PUSH OR TOW A
identifies gear lubricants in terms of recommended VEHICLE TO START THE ENGINE. UNBURNED
usage. FUEL COULD ENTER THE EXHAUST CATALYTIC
CONVERTER AND IGNITE AFTER THE ENGINE IS
CHASSIS COMPONENT AND WHEEL BEARING STARTED. THIS COULD CAUSE THE CONVERTER
LUBRICANTS TO OVERHEAT AND RUPTURE
The chassis component and wheel bearing lubri
cants are identified by the NLGI Certification Sym
bol (Fig. 4). BOOSTER BATTERY
WARNING: TO PREVENT PERSONAL INJURY OR

NATIONAL LUBRICATING
GREASE INSTITUTE CLOTHING DAMAGE, DO NOT ALLOW BATTERY
-CERTIFICATION (ACID) TO CONTACT EYES, SKIN OR CLOTHING.
SYMBOL
NLGI
AUTOMOTIVE
DO NOT LEAN OVER A BATTERY WHEN CON
NECTING "JUMPER CABLES".DO NOT ALLOW THE
POSITIVE AND NEGATIVE CABLE CONNECTOR
WHEEL BEARING & CHASSIS
LUBRICANT CLAMPS TO CONTACT EACH OTHER. KEEP OPEN
FLAMES AND SPARKS AWAY FROM THE BATTERY
-USAGE AND
GC-LB QUALITY D E S I G N A T I O N
VENT HOLES. ALWAYS WEAR EYE PROTECTION
WHEN INVOLVED WITH BATTERIES.
If it is necessary to use a "booster" battery and

"jumper" cables to start an engine use the following
J9200-57
procedure.
Fig. 4 NLGI Lubricant Certification/Identification (1) Engage the parking brake and shift the auto
Symbol matic transmission to PARK (if a manual transmis
The letter G indicates wheel bearing lubricant and sion, shift to NEUTRAL).
the letter L indicates chassis lubricant. When the (2) Turn off all lights, the heater-A/C blower mo
letters are combined the lubricant can be used for tor, and all other electrical loads.
dual applications. The suffix letters C and B indi (3) Pry the vent caps from the discharged battery
cates quality level of the lubricant. Use only lubri with a flat, non-metallic tool and remove the caps.
cants that display the NLGI Certification Symbol It could possibly be necessary to loosen the battery
(Fig. 4). holddown clamp to remove the vent caps. Inspect the
0 - 4 L U B R I C A T I O N A N D MAINTENANCE J
REQUIRED LUBRICATION & MAINTENANCE SCHEDULE-XJ/YJ VEHICLES
SCHEDULED MAINTENANCE JEEP 2.5L/4.0L - CALIFORNIA
'Miles (Thousand) 7.5 15 22.5 30 37.5 45

Kilometers 12 24 36 48 60 72.5
EMISSION RELATED
Air Cleaner Air filter — Replace X
Drive Belt — Adjust X
Spark Pluqs — Replace X
NON EMISSION RELATED
Enqine Coolant — Check — Level, Hoses, Clamps X X X X X X
Engine Coolant — Flush and Replace at 36 Months
Thereafter — Flush and Repalce every 24 Months
Engine Oil — Change Every 6 Months or X X X X X X
Engine Oil Filter — Replace X X X X X X
Exhaust System — Check X X X X X X
Months 6 12 18 24 30 36
' Where both time and distance are indicated, follow the interval which occurs first.
X = Scheduled maintenance for all vehicles. J9300-26
REQUIRED LUBRICATION & MAINTENANCE SCHEDULE-XJ/YJ VEHICLES
SCHEDULED MAINTENANCE JEEP 2.5L/4.0L - (Except California)

Wiles (Thousand) 7.5 15 22.5 30 37.5 45 52.5 60
Kilometers 12 24 36 48 60 72.5 84.5 96.5
EMISSION RELATED
Air Cleaner Air filter — Replace X X
Distributor Cap and Rotor — Replace X X
Ignition Wires — Replace X
Spark Plugs — Replace X X
NON EMISSION RELATED
Drive Belt — Adjust X X
Drive Belt — Replace X
Engine Coolant — Check — Level, Hoses, Clamps X X X X X X X X
Engine Coolant — Flush and Replace at 36 Months or X
Thereafter — Flush and Repalce every 24 Months or
Engine Oil — Change Every 6 Months or X X X X X X X X
Engine Oil Filter — Replace X X X X X X X X
Exhaust System — Check X X X X X X X X
Fuel Filter — Replace X
Months 6 12 18 24 30 36 42 48
1
W h e r e both time and distance are indicated, f o l l o w the interval which occurs first.
X = Scheduled maintenance f o r all vehicles. J9300-27
battery (acid) level. If it is too low, the electrolyte (4) Inspect the general condition of the battery
level must be increased to the correct level before electrolyte.
"jump" starting. (5) Install vent caps on the discharged battery vent
wells. A relief valve in the cap prevents pressure
WARNING: W H E N T H E A I R T E M P E R A T U R E I S B E build-up.
L O W T H E F R E E Z I N G POINT (0°C OR 32°F), T H E
ACID IN A D I S C H A R G E D V E H I C L E B A T T E R Y CAN CAUTION: Do not permit metal surfaces on vehicles
F R E E Z E . DO NOT A T T E M P T T O " J U M P " S T A R T AN to contact because this could establish ground con
ENGINE B E F O R E D E T E R M I N I N G T H E CONDITION tinuity between vehicle bodies.
OF T H E B A T T E R Y *
J L U B R I C A T I O N AND MAINTENANCE 0 - 5
RECOMMENDED LUBRICATION & MAINTENANCE SCHEDULE-XJ/YJ VEHICLES
COMPONENT SERVICE K I L O M E T E R S (MILEAGE) O R T I M E I N T E R V A L
STEERING L I N K A G E - 2 W D LUBRICATE E V E R Y 24 000 km OR 6 M O N T H S

STEERING L I N K A G E - 4 W D LUBRICATE EVERY 12 000 km OR 6 M O N T H S
MANUAL TRANSMISSION D R A I N & REFILL

NORMAL DRIVING CONDITIONS EVERY 60 000 k m
SEVERE DRIVING C O N D I T I O N S * EVERY 29 000 k m
AUTOMATIC TRANSMISSION D R A I N & REFILL
NORMAL DRIVING CONDITIONS EVERY 48 000 km
SEVERE DRIVING C O N D I T I O N S EVERY 29 000 km
T R A N S F E R CASE D R A I N & REFILL EVERY 48 000 km
FOR DETERIORATION A N D L E A K S W H E N E V E R B R A K E
B R A K E HOSES INSPECT S Y S T E M IS SERVICED A N D EVERY OIL C H A N G E —
REPLACE IF NECESSARY.
DRIVE S H A F T U N I V E R S A L J O I N T S LUBRICATE
NORAAAL D R I V I N G CONDITIONS EVERY 12 000 km
SEVERE DRIVING C O N D I T I O N S * EVERY 4 800 km
F R O N T & REAR A X L E S D R A I N & REFILL
NORAAAL D R I V I N G CONDITIONS EVERY 48 000 km
SEVERE DRIVING C O N D I T I O N S * EVERY 29 000 km
* A severe driving condition is defined as: Frequent driving in "dusty" conditions; extensive idling; frequent starting and stopping; operating at sustained
high speeds during hot weather (above + 3 2 ° G : commercial ODeration: off-road drivina; cold-climate operation; desert operation; or trailer towing.
J9200-72
(6) Attach a red cable connector clamp to the pos WARNING: DO NOT CONNECT A " J U M P E R " CA
itive ( + ) terminal on the booster battery. Connect B L E CONNECTOR C L A M P T O T H E N E G A T I V E
the other red cable connector clamp to the positive P O S T OF T H E D I S C H A R G E D B A T T E R Y .
( + ) terminal on the discharged battery (Fig. 5).
(7) Connect a black "jumper" cable connector
CAUTION: Use care to avoid allowing the positive clamp to the negative (-) terminal on the booster bat
( + ) and negative (-) cable clamps to contact each tery. Connect the other black "jumper" cable connec
other. DO N O T lean over the battery when connect tor clamp to a good ground.
ing the cable clamps. (8) Start the engine.
0 - 6 L U B R I C A T I O N A N D MAINTENANCE
J
FLUID CAPACITIES
CAPACITIES
ENGINE OIL QUARTS LITERS API SERVICE GRADES
2.5L Engine 4.0 3.8 SG, SG/CD or SG/CE

4.0L Engine 6.0 5.7 SG, SG/CD or SG/CE
COOLING SYSTEM QUARTS LITERS
2 . 5 L Engine (XJ Vehicles) 10.0* 9.5*

2.5L Engine (YJ Vehicles) 9.0 * * 8.5 * *
4 . 0 L Engine (XJ Vehicles) 12.0* 11.4*
4 . 0 L Engine (YJ Vehicles) 10.5** 9.9**
* Includes 2.3 q t . / 2 . 2 L for coolant reserve/recovery reservoir. * * Includes 1 qt./0.9L for coolant recovery reserve reservoir.
TRANSMISSIONS (APPROX. CHANGE CAPACITIES) PINTS LITERS TYPE
AX-5 (4 WD) 7.0 3.3 Man. 5 Speed

AX-15 (4 WD) 6.75 3.2 Man. 5 Speed
AX-5 (2 WD) 7.4 3.5 Man. 5 Speed
AX-15 (2 WD) 6.7 3.15 Man. 5 Speed
AW-4 (J Vehicles) 8.5* 4.0* Automatic
999 (YJ Vehicles) 8.0* 3.8* Automatic
Use API GL5/SAE 75W-90 grade lubrication for manual transmissions. Use MERCON* type ATF for AW-4 automatic transmission.
Use DEXRON II® or ATF PLUS type ATF for 999 automatic transmission. 'Quantity will vary according to amount of ATF that
remained in the converter.
FRONT/REAR AXLES PINTS LITERS API QUALITY GRADE/SAE VISCOSITY
XJ Vehicles (1) (3) 2.5 1.2 API GL5/SAE 75W-90

YJ Vehicles (3) (2) 2.5 1.2 API GL5/SAE 75W-90
Heavy Duty Rear Axle (3) (2) 3.0 1.4 API GL5/SAE 75W-90
(1) With Trailer Two Class III Hitch (5000 lbs) use 75W-140 Synthetic Gear Lubricant in rear axle.
(2) With Trailer Two Package use API GL5 80W-140 Lubricant in rear axle.
(3) With Rear Axle Limited Slip Differential, Add 2 ounces of Friction Modifier Additive.
TRANSFER CASE PINTS LITERS TYPE ATF
SELEC-TRAC 242 (XJ Vehicles) 3.0 1.4 ATF PLUS, MERCON® or DEXRON II®
COMMAND-TRAC 231 (XJ VEHICLES) 2.2 1.0 ATF PLUS, MERCON® or DEXRON II®
COMMAND-TRAC 231 (YJ VEHICLES) 3.25 1.5 ATF PLUS, MERCON® or DEXRON II®
FUEL TANK GALLONS LITERS
XJ Vehicles 20.2 76.4

YJ Vehicles (Standard) 15.0 56.8
YJ Vehicles (Optional) 20.0 75.7
J9300-28
LUBRICATION AND MAINTENANCE 0 - 7
POSITIVE NEGATIVE
CABLE OH G R O U N D
CONNECTION CABLE
CONNECTION
SUB-FRAME
RAIL LOCATION
BOOSTER BATTERY J8900-7
Fig. 5 "Jumper" Cable Connections

SUB-FRAME
WARNING: THE USE OF ANY "JUMPER" CABLE RAIL LOCATION
DISCONNECTION PROCEDURE OTHER THAN THAT
DESCRIBED BELOW COULD RESULT IN:
J9000-24
• PERSONAL INJURY CAUSED BY BATTERY

ELECTROLYTE SQUIRTING FROM THE BAT Fig. 6 Correct Vehicle Lifting Locations— Typical
TERY VENTS; CAUTION: Do not attempt to lift a Jeep® vehicle
• PERSONAL INJURY AND/OR PROPERTY DAM with a floor jack positioned under:
AGE CAUSED BY BATTERY EXPLOSION;
AND/OR • an axle tube,
• DAMAGE TO THE BOOSTER VEHICLE OR THE • a body side sill,
DISABLED VEHICLE CHARGING SYSTEM. • a steering linkage component,
(9) After the engine is started, or if the engine • a drive shaft,
fails to start, the "jumper" cables must be discon • the engine or transmission oil pan,
• the fuel tank, or
nected in the following order:
• a front suspension arm.
• black (negative) cable connector clamp from the
Use the correct sub-frame rail or frame rail
engine ground contact;
lifting locations only (Fig. 6).
• black (negative) cable connector clamp from the
negative terminal (-) on the booster battery; and HOIST
• red (positive) cable connector clamps from the pos A Jeep® vehicle can be lifted with a swiveling-arm
itive ( + ) terminals on both batteries. type hoist; with a wheel-lift, twin-post hoist; or with
a ramp-type, drive-on hoist.
PORTABLE STARTING UNIT When a swiveling-arm, frame-contact type
There are many types of portable starting units hoist is used, ensure that the lifting pads are po
available for starting engines. Follow the manufac sitioned at the correct sub frame rail (Fig. 6).
turer's instructions when involved in any engine
starting procedure. VEHICLE TOWING RECOMMENDATIONS
FLOOR JACK TOWING EQUIPMENT
When properly positioned, a floor jack can be used A vehicle equipped with SAE approved "sling-type"
to lift a Jeep® vehicle. Support the vehicle in the towing equipment can be used to tow all Jeep® vehi
raised position with jack stands at the front and rear cles (Fig. 7 ) . When it is necessary to "rear-tow" a ve
ends as applicable (Fig. 6). hicle, use the "wheel-lift" towing method with a tow
"dolly" located under the front wheels. A vehicle
0 - 8 L U B R I C A T I O N A N D MAINTENANCE
J
with "flat-bed" towing equipment can also be used to • avoid towing distances of more than 24 km (15
transport a disabled vehicle (Fig. 7). miles) whenever possible; and
• do not attach tow chains or a tow sling to a
bumper, the steering linkage, the universal joints,
the constant velocity (CV) joints, or a drive shaft.
CLEARANCES AND RAMP ANGLE

SLING-TYPE SURFACE CLEARANCE
The end of the disabled vehicle that is attached to
the tow vehicle should be lifted a minimum of 10 cm
or four inches off the surface. Inspect to ensure that
the opposite end of the disabled vehicle has clearance
from the surface.
FLAT BED RAMP ANGLE-FLAT-BED TOWING

J9000-28
If a vehicle with "flat-bed" towing equipment is
Fig. 7 Tow Vehicles With Approved Equipment used, the approach ramp angle should not exceed 15
degrees.
A wooden crossbeam with spacer blocks could pos
sibly be required for proper connection when using SLING-TYPE, FRONT-END TOWING
the sling-type, front-end towing method (Fig. 8).
XJ VEHICLES
Use the following guidelines when the tow vehicle
is attached to the front end of a disabled vehicle.
(1) Always tow with the front wheels lifted off the
surface and turned all the way to the right.
SPACERBLOCKS CAN B E (2) Attach a J-hook to the disabled vehicle at the
FABRICATED A S S H O W N left side of the axle (Fig. 9).
AAATERIAL-SPACER B L O C K S
4 - 2 X 4 X 6 " LONG J-HOOK
4 X 4 LUMBER 2 - 4 X 4 X 3 - 1 / 2 " LONG
ACTUALLY 8- 1 / 4 " X 7 " C A R R I A G E B O L T
MEASURES 8- 1 / 4 " N U T
3-1/2" X 3 - 1 / 2 " 16- 1 / 4 " W A S H E R J9000-48
Fig. 8 Crossbeam & Spacer Block Construction

SAFETY PRECAUTIONS
The following safety precautions must be consid
ered when preparing for and during a vehicle towing
operation:
• if the vehicle is damaged, secure the loose and pro
truding parts;
• always use a safety chain system that is indepen
dent of the lifting and towing equipment;
• do not allow any of the towing equipment to con
tact the disabled vehicle's fuel tank; F R Q N T VI j W
J9000-20
• do not allow anyone to be under the disabled vehi
cle while it is lifted by the towing equipment; Fig. 9 Sling-Type, Front-End Towing (XJ Front View)
• do not allow passengers to ride in a vehicle being
towed; (3) Position the sling crossbar close to the J-hook
• always observe all state and local laws involving and below the front bumper (Fig. 9).
warning signals, night illumination, speed, etc. (4) Secure a chain to the right side of vehicle by
• do not attempt a towing operation that could jeop placing it over the axle shaft tube and attaching it to
ardize the safety of the operator, bystanders or other a structural member (Fig. 10).
motorists; (5) Attach the safety chains to the vehicle.
• do not exceed a towing speed of 48 km/h (30 mph); 2WD With Manual Or Automatic Transmission
LUBRICATION AND MAINTENANCE 0 -9
J
YJ VEHICLES
Use the following guidelines when the tow vehicle
is attached to the front of a disabled vehicle.
(1) Always tow with the front wheels lifted off the
surface and turned all the way to the right.
CAUTION: U s e tow chains with T-hooks f o r con

necting to the disabled vehicle's frame rails (Fig.
11). Never use J-hooks.
Fig. 10 Sling-Type, Front-End Towing (XJ Rear

View)
(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(7) Shift the transmission to NEUTRAL, mark the
drive shaft and axle drive pinion gear shaft yoke for Fig. 11 Tow Chains & Hooks
installation reference. Remove the drive shaft from
the vehicle. (2) Attach the T-hooks to the slots in the front end
(8) Cover the exposed end of the transmission ex of each frame rail (Fig. 12).
tension housing and the universal joints. Store the
drive shaft in a safe place.
4WD, Command-Trac (231 Part-Time 4WD
Transfer Case) And Manual Transmission
When the transfer case is in the NEUTRAL po
sition, both axles are disengaged from the pow
ertrain. This allows the vehicle to be towed
without removing the drive shafts.
(7) Shift the manual transmission into a forward
gear and the transfer case to NEUTRAL.
4WD, Command-Trac (231 Part-Time 4WD
Transfer Case) And Automatic Transmission
When the transfer case is in the NEUTRAL po
(7) Shift the automatic transmission to PARK and Fig. 12 Sling-Type, Front-End Towing (YJ Vehicles)
the transfer case to NEUTRAL. (3) Position each safety chain over the top of each
4WD, Selec-Trac (242 Full-Time 4WD Transfer front spring and inboard of each front spring shackle
Case) And Automatic Transmission (Fig. 12).
(6) Turn the ignition switch to the OFF position to (4) Double wrap each chain.
unlock the steering wheel. (5) Position the sling crossbar under the front
When the transfer case is in the NEUTRAL po bumper.
sition, both axles are disengaged from the pow Command-Trac (231 Part-Time 4WD Transfer
Case) And Manual Transmission
(7) Shift the automatic transmission to PARK and
the transfer case to NEUTRAL.
0 - 10 LUBRICATION AND MAINTENANCE J
When the transfer case is in the NEUTRAL po (5) Clamp the steering wheel with the front wheels
sition, both axles are disengaged from the pow in the straight ahead position. Do not use the steer
ertrain. This allows the vehicle to be towed ing column lock as a substitute for a clamping de
without removing the drive shafts, vice.
(7) Shift the manual transmission to a forward When the transfer case is in the NEUTRAL po
gear and the transfer case to NEUTRAL. sition, both axles are disengaged from the pow
Command-Trac (231 Part-Time 4WD Transfer ertrain. This allows the vehicle to be towed
Case) And Automatic Transmission without removing the drive shafts.
(6) Turn the ignition switch to the OFF position to (6) Shift the transmission to PARK and the trans
unlock the steering wheel. fer case to NEUTRAL.
When the transfer case is in the NEUTRAL po 4WD, Selec-Trac (242 Full-Time 4WD Transfer
sition, both axles are disengaged from the pow Case) And Automatic Transmission
ertrain. This allows the vehicle to be towed (4) Turn the ignition switch to the OFF position to
without removing the drive shafts. unlock the steering column.
(7) Shift the automatic transmission to PARK and (5) Clamp the steering wheel with the front wheels
the transfer case to NEUTRAL. in the straight ahead position. Do not use the steer
ing column lock as a substitute for a clamping de
SUNQ-TYPE, REAR-END TOWING vice.
Y J VEHICLES-use wheel-lift equipment ONLY When the transfer case is in the NEUTRAL po
when towing from the rear end of the vehicle is nec sition, both axles are disengaged from the pow
essary. ertrain. This allows the vehicle to be towed
Use the following guidelines for XJ vehicles when without removing the drive shafts.
the tow vehicle is attached to the rear of the disabled (6) Shift the transmission to PARK and the trans
vehicle. fer case to NEUTRAL.
(1) Attach J-hooks around the axle shaft tubes out 4WD, Selec-Trac (229 Full-Time 4WD Transfer
board of the shock absorber. Case) and Automatic Transmission
(2) Place the sling crossbar under and forward of When the transfer case range selector is in the
the bumper. NEUTRAL position, both axles are disconnected
(3) Attach safety chains around the frame rails. from the powertrain. This allows the vehicle to
2WD With Manual Or Automatic Transmission be towed without removing the drive shafts.
(4) Turn the ignition switch to the OFF position to (4) Shift mode switch to the 4WD position.
unlock the steering wheel. (5) With the vehicle moving slowly (3-5 km/h or
(5) Clamp the steering wheel with the front wheels 2-3 mph), shift the transmission to the NEUTRAL
in the straight ahead position. Do not use the steer (N) position.
ing column lock as a substitute for a clamping de Use a firm, positive hand movement to shift
vice. the range selector lever to the NEUTRAL (N) po
(6) Shift the transmission to NEUTRAL. sition.
4WD, Command-Trac (231 Part-Time 4WD (6) Turn ignition key switch to the unlock (OFF)
Transfer Case) And Manual Transmission position.
(4) Turn the ignition switch to the OFF position to (7) Shift the automatic transmission to the PARK
unlock the steering column. (P) position.
(5) Clamp the steering wheel with the front wheels TOWING WHEN IGNITION KEYS ARE NOT
in the straight ahead position. Do not use the steer AVAILABLE
ing column lock as a substitute for a clamping de
vice. VEHICLE DOORS UNLOCKED
When the transfer case is in the NEUTRAL po 2WD Vehicles
sition, both axles are disengaged from the pow Either one of two methods can be used:
ertrain. This allows the vehicle to be towed • tow the vehicle with the drive shaft removed (refer
without removing the drive shafts. to Sling-Type, Front-End Towing); or
(6) Shift the transmission to a forward gear and • place a tow dolly under the rear wheels (Fig. 13)
the transfer case to NEUTRAL. and tow with the front end raised (refer to Sling-
4WD, Command-Trac (231 Part-Time 4WD Type, Front-End Towing).
Transfer Case) And Automatic Transmission 4 WD, Command-Trac (231 Part-Time 4WD
(4) Turn the ignition switch to the OFF position to Transfer Case) And Manual Transmission
unlock the steering column. (1) Shift the manual transmission to a forward
gear.
4WD EMERGENCY TOWING-TRANSFER CASE

NOT SHIFTED TO NEUTRAL
When a situation arises and the transfer case can
not be shifted to NEUTRAL, any of the following
methods can be used to tow a 4WD vehicle.
Drive shafts not removed, place the rear
wheels on a tow dolly and tow with the front
end raised.
Drive shafts not removed, place the front
wheels on a tow dolly and tow with the rear end
raised.
Rear drive shaft removed, tow with the front
end raised.
Front drive shaft removed, tow with the rear
end raised.
Fig. 13 Sling-Type, Front-End Towing With Rear Both drive shafts removed, tow with all four
Wheels On A Tow Doily wheels on the road surface.
(1) Turn ignition key switch to the unlocked (OFF)
When the transfer ease is in the NEUTRAL po position.
sition, both axles are disengaged from the pow (2) Shift the transmission to the NEUTRAL posi
ertrain. This allows the vehicle to be towed tion.
without removing the drive shafts. (3) Determine the method by which the vehicle
(2) Shift the transfer case to NEUTRAL. will be towed and prepare the vehicle for towing.
(3) The vehicle can now be towed with the front (4) Connect the vehicle to the tow vehicle. Refer to
wheels raised (refer to Sling-Type, Front-End Tow the applicable procedure.
ing).
4WD, Command-Trac (231 Part-Time 4WD FLAT TOWING (4 TIRES/WHEELS ON
Transfer Case) And Automatic Transmission SURFACE)
(1) Check and ensure that the automatic transmis Tow a vehicle in this manner only when all four
sion is in PARK. wheels will freely rotate. Prepare the vehicle accord
When the transfer case is in the NEUTRAL po ing to the following procedures.
ertrain. This allows the vehicle to be towed 2WD VEHICLES
without removing the drive shafts. (1) Mark the drive shaft and the axle drive pinion
(2) Shift the transfer case to NEUTRAL. gear shaft yoke for installation alignment reference.
(3) The vehicle can now be towed with the front (2) Remove the drive shaft. Install a protective
wheels raised (refer to Sling-Type, Front-End Tow covering over the drive shaft U-joints to retain them
ing). assembled and protected.
4WD, Selec-Trac (242 Full-Time 4WD Transfer (3) Cover the open end of the transmission exten
Case) And Automatic Transmission sion housing.
(1) Check and ensure that the automatic transmis
sion is in PARK. 4WD VEHICLES
When the transfer case is in the NEUTRAL po (1) Mark the drive shafts and the axle drive pinion
sition, both axles are disengaged from the pow gear shaft yokes for installation alignment reference.
ertrain. This allows the vehicle to be towed (2) Remove the drive shafts. Install a protective
without removing the drive shafts. covering over the drive shaft U-joints/CV-joints to re
(2) Shift the transfer case to NEUTRAL. tain them assembled and protected.
(3) The vehicle can now be towed with the front (3) Cover the exposed ends of the transfer case.
wheels raised (refer to Sling-Type, Front-End Tow
ing). CAUTION: Whenever a drive shaft has been re
moved and installed, check the transmission fluid
VEHICLE DOORS LOCKED level on the dipstick. Driving a vehicle with low
Place a tow dolly under the rear wheels (Fig. 13) transmission fluid can damage the transmission.
and tow with the front end raised (refer to Sling-
Type, Front-End Towing).
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A

VEHICLE THAT IS BEING TOWED VIA ITS T O W
HOOKS. THE TOW^STRAPS/CHAINS COULD POSSI
BLY BREAK AND CAUSE SERIOUS INJURY.
Some Jeep® vehicles are equipped with emergency

tow hooks located at the front end (Fig. 14). Some
Jeep® vehicles also have emergency tow hooks lo
cated at the rear ende. The tow hooks should be used
for EMERGENCY purposes only.
CAUTION: DO NOT use emergency tow hooks for

tow truck hook-up or highway towing.
Vehicles
J LUBRICATION AND MAINTENANCE 0 -13
ENGINE MAINTENANCE
INDEX
page page
Air-Conditioner Compressor/Hoses/Fittings 26 Engine Supports 25
Battery 24 Exhaust System 26
Cooling System . 16 Fuel System 20
Crankcase Ventilation System 20 Ignition Cables, Distributor Cap and Rotor . . . . . . 22
Drive Belt 26 Oxygen ( 0 ) Sensor
2 23
Engine Air Cleaner Filter Element 18 Rubber and Plastic Ducts/Hoses/Tubing 24
Engine Break-In . 13 Spark Plugs 23
Engine Oil . 13 Vacuum Operated, Emission Control
Engine Oil Change and Filter Replacement 15 Components 22
Engine Oil Filter 15
ENGINE BREAK-IN AMBIENT RECOMMENDED

TEMPERATURE OILS, SAE
After first starting a new engine, allow it to idle RANGE
and warm up for at least 15 seconds before shifting
the transmission into a drive gear.
Drive the vehicle at:
• varying speeds less than 80 km/h (50 mph) for the
first 160 km (100 miles), and
• speeds less than 88 km/h (55 mph) for the first 800 60°F
(16°Q
km (500 miles).
Avoid driving at full-throttle for extended periods
of time. Also, avoid fast acceleration and sudden 10W-30
stops.
A special "break-in" engine oil is not required. The 5W-30
original oil installed in a vehicle is a quality lubri
cant. There is no requirement to have the oil 0°F
changed or the oil filter replaced until the first (-18°C)
scheduled maintenance interval.
The engine oil, coolant and all the other engine re
lated fluid levels should be determined on a regular
basis. J9000-26
ENGINE OIL Fig. 1 Temperature/Engine Oil Viscosity

SPECIFICATIONS ENERGY CONSERVING OIL
In selecting the correct API grade and SAE grade,
API SERVICE GRADE an ENERGY CONSERVING type engine oil is also
For maximum engine protection during all driving recommended.
conditions, install an engine oil that conforms to API
Service Grade. MOPAR Engine Oil conforms to all of CONTAINER IDENTIFICATION
these API Service Grades. Standard engine oil notations have been adopted
for selection of engine oil. The notations are located
SAE VISCOSITY on side of plastic bottles and on the top of engine oil
SAE designated multi-viscosity grade engine oil is cans (Fig. 2).
to protect engines. This type of engine oil can usually • The top, outer field contains the A P I Service
be installed and remain in the engine until the next Grade notation for the engine oil.
scheduled oil change. Select the engine oil viscosity • The center field contains the SAE viscosity
according to the lowest ambient air temperature ex grade notation for the engine oil.
pected before the next scheduled oil change. Low vis
• The lower, outer field contains either the EN
cosity engine oil allows easier engine starting during
ERGY CONSERVING or the ENERGY CON
cold weather. SAE 5W-30 viscosity engine oil is rec
SERVING I I notation for the engine oil.
ommended when the ambient air temperatures con
sistently decrease to below 10°F (-12°C).
five minutes after stopping the engine. Add engine

oil only when the level indicated on the dipstick is at
or below the ADD mark.
ECONOMY
J 9 1 0 C M
NOTATION
Fig. 2 Engine Oil Container Standard Notations

CAUTION: Non-detergent engine oil or straight-min
eral oil must never be used to lubricate a Jeep® en
gine. These type of oils will not provide proper Fig. 4 Engine Oil Dipstick—2.5L Engine
engine lubrication and can result in engine damage.
LEVEL INDICATOR (DIPSTICK)

The engine oil level indicator is located at the right
rear of both 2.5L engines and 4.0L engines (Fig. 3).
Fig. 5 Engine Oil Dipstick—4.0L Engine

CAUTION: Do not overfill the engine crankcase with
oil. This will cause oil aeration and result in a de
crease in the engine oil pressure.
ADDITIVES
It is not necessary to add a special "additive" to en
gine oil for most types of vehicle operation. However,
J9200-25
the addition of special "additives" containing anti-
Fig. 3 Engine Oil Dipstick Location—Typical rust and anti-scuff compounds can be helpful in some
instances. For example:
ACCEPTABLE LEVEL • with infrequent vehicle operation or short-trip only
To ensure proper lubrication of an engine, the en operation, or
gine oil must be maintained at an acceptable level. • during engine "break-in" after a major engine
The acceptable levels are indicated between the ADD overhaul and/or replacement piston installation.
and FULL marks on the engine oil dipstick (Figs. 4 MOPAR Engine Oil Supplement (or an equivalent
and 5). The engine oil level should be determined at product) is acceptable for the conditions listed above.
the end of each regular driving interval. The vehicle
should be on a level surface. Wait for approximately
J L U B R I C A T I O N AND MAINTENANCE 0 -1 5
ENGINE O I L F I L T E R
FILTER SPECIFICATION
All Jeep® engines are equipped with a high quality
full-flow, throw-away type oil filter. The same type of
replacement oil filter is recommended when a re
placement is required.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
WARNING: C A R E S H O U L D B E T A K E N W H E N
CHANGING O I L . P R O T E C T I V E CLOTHING AND
GLOVES SHOULD B E WORN. E X P O S E D SKIN
S H O U L D BE W A S H E D W I T H S O A P AND W A T E R T O
R E M O V E A N Y ENGINE OIL. DO N O T U S E GASO
OIL FILTER J90004
LINE, THINNER, OR S O L V E N T S T O REMOVE EN
GINE OIL FROM S K I N . Fig. 6 Oil Filter Removal—2.5L Engine
REQUIRED MAINTENANCE
With normal driving conditions, engine oil and fil
ter must be changed after each 12 000-km (7,500-
miles)/12-month interval. If the vehicle is involved
with a severe driving condition, after each 4 800-km
(3,000-miles)/3-month interval. A severe driving con
dition includes:
• frequent short trip driving less than 24 km (15
miles);
• frequent driving in a "dusty" environment;
• trailer towing;
• extensive engine idling;
• sustained high-speed operation;
OIL FILTER J9000-7
• desert operation;
• frequent starting and stopping; Fig. 7 Oil Filter—4.0L Engine
• cold-climate operation;
• off-road driving; or (6) Install and hand tighten the oil filter 1/2 to
• commercial service. 3/4 of-a-turn clockwise beyond the point where the
seal first contacts the cylinder block.
OIL CHANGE AND FILTER REPLACEMENT (7) Add engine oil in fill hole located on top of en
(1) Drain the engine oil from the crankcase. Wait gine cylinder head cover (Fig. 8).
until after the engine has attained the normal oper (8) Observe the oil level on the "dipstick". Add oil,
ating temperature to ensure complete drainage of oil. if necessary, to increase the level to the FULL mark.
(2) Install the drain-hole plug with a replacement
gasket. CAUTION: Do not overfill the engine crankcase with
The oil filter should be replaced during every oil. T h i s will cause oil aeration and result in a de
engine oil change. crease in the engine oil pressure.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Figs. 6 and (9) Start the engine and observe the oil pressure
7). gauge or warning lamp. If the pressure does not in
(4) Clean the cylinder block oil filter boss. crease or the warning lamp does not go out, stop the
(5) Apply a light coat of engine oil to the rubber engine and determine the cause of the problem.
seal on the replacement oil filter.
USED ENGINE OIL DISPOSAL
CAUTION: T h e engine oil filter on all 1992 Jeep® en Care should be exercised when disposing "used" en
gines has S A E type 3/4X16 threads. T h e use of an gine oil after it has been drained from a vehicle en
oil filter with incorrect threads can result in engine gine. Refer to the WARNING listed above.
oil leakage and possible engine damage. Ensure
that the replacement filter i s correct for the engine.
0-18 LUBRICATION AND MAINTENANCE J
DRAIN, FLUSH AND FILL
DRAINING AND FLUSHING SYSTEM
WARNING: DO N O T OPEN T H E DRAINCOCK OR

R E M O V E T H E C Y L I N D E R B L O C K DRAIN P L U G /
COOLANT S E N S O R W H E N T H E COOLING S Y S T E M
I S H O T AND P R E S S U R I Z E D .
Do not remove the radiator cap when draining the

cooling system. This will allow the coolant from the
recovery bottle to drain along with the coolant from
the radiator and cylinder block.
(1) If the cooling system has water valves to con
trol coolant flow through the heater, place the heater
control in the HEAT position.
(2) Place a container under the cylinder block
drain plug and the under radiator draincock.
(3) Open the radiator draincock (Fig. 9).
Fig. 8 Adding Engine Oil—Typical

COOLING SYSTEM
WARNING: U S E E X T R E M E CAUTION W H E N I F T H E
ENGINE I S O P E R A T I N G . DO N O T P U T Y O U R
HANDS N E A R T H E D R I V E B E L T ( S ) , P U L L E Y S O R
FAN B L A D E . DO N O T S T A N D IN A D I R E C T L I N E
W I T H T H E FAN B L A D E .
RECOMMENDED MAINTENANCE
The engine coolant level should be determined at
least once a month and more often during periods of
hot weather. Add coolant as necessary.
COOLANT LEWEL
With the engine at normal operating temperature,
observe the coolant level in the coolant recovery
bottle. The coolant level must be at least above the
ADD mark and preferably at the FULL mark. Add Fig. 9 Radiator Draincock (4.0L)—Typical
coolant to the coolant recovery bottle only, if neces
sary. (4) For 4.0L engines, remove the cylinder block
drain plug or coolant temperature sensor (Fig. 10).
REQUIRED MAINTENANCE For 2.5L engines, remove the cylinder block drain
Check coolant level, and inspect condition of cool plug.
ing system hoses and clamps after each 12 000-km (5) Allow the coolant to completely drain from the
(7,500-miles). radiator, recovery bottle and cylinder block.
Initially, coolant must be drained and cooling sys Care should be taken when disposing coolant
tem flushed and filled after the first 86 months of op after it is drained from cooling system. Coolant
eration. Thereafter, after each 24-months interval of when disposed, could create a problem for the
environment.
vehicle operation.
(6) Remove coolant containers from under cylinder
block drain plug and radiator draincock. Empty con
tainers.
(7) Place the coolant containers under the cylinder
block drain plug and the radiator draincock.
The engine cooling system should be inspected for
proper operation and for component failure at least
every 12 months.
WARNING: I F T H E ENGINE H A S B E E N R E C E N T L Y
O P E R A T E D , U S E E X T R E M E C A R E W H E N REMOV
ING T H E R A D I A T O R CAP T O AVOID SCALDING
W I T H H O T , P R E S S U R I Z E D COOLANT.
(1) Inspect the general condition of the cooling sys

tem hoses and clamps. Replace as necessary.
THERMOSTAT
HOUSING
RADIATOR
COOLANT BLOCK
TEMPERATURE DRAIN
SENSOR PLUG J9107-65
Fig. 10 Drain Plug & Coolant Temperature Sensor

(4.0L)—Typical
(8) Flush the cooling system with an appropriate
flushing device.
(9) Clean the drain plug threads and coat them
with pipe thread sealer. Install the drain plug in the
cylinder block.
(10) Close the radiator draincock. RADIATOR-
TO-WATER
THERMOSTAT
P U M P (LOWER)
FILLING SYSTEM HOUSING-TO-
HOSE
RADIATOR
(1) Remove the radiator cap and the coolant recov (UPPER)
ery bottle cap. HOSE J9200-19
(2) Slowly fill the radiator to the bottom of the
filler neck with the recommended coolant mixture. Fig. 11 Radiator Upper & Lower Hoses/Clamps (YJ
(3) Slowly fill the coolant recovery bottle to the 2.5L)—Typical
FULL mark on the bottle. (2) Test the radiator cap for proper vacuum sealing
(4) If cooling system has water valves to control and operation.
coolant flow through heater, place heater control in Use caution when removing the radiator cap
HEAT position. to avoid contact with coolant and steam. Place a
(5) Start the engine and allow it to attain normal heavy rag or towel over the cap and turn to the
operating temperature. first stop. Do not press down. Pause to allow the
(6) Observe the coolant level in the radiator filler pressure to release through overflow tube, then
neck. As necessary, add coolant until the level is at press down and turn counterclockwise to re
the bottom of the filler neck. move cap.
(7) Install the radiator and recovery bottle caps. (3) Inspect condition of coolant overflow tubing and
(8) Inspect the cooling system for leaks. connections at recovery bottle and radiator (Fig. 14).
(9) Stop the engine and allow it sufficient time to (4) Pressurize the cooling system (Fig. 15) and in
cool. spect the entire cooling system for coolant leaks. A
(10) Observe the coolant level in the recovery bot black-light detector can be used as an aid in detect
tle. As necessary, add coolant until level is between ing the source of coolant leaks (Fig. 16).
ADD and FULL marks on the bottle. Black-light detection dye is factory-installed in
If necessary, refer to Group 7-—Cooling Systems for Jeep® cooling systems and, unless the coolant
additional information. has been drained and re-filled, it is not neces
sary to add dye.
0-18 LUBRICATION AND MAINTENANCE J
THERMOSTAT RECOVERY FENDER

HOUSING-TO- HOSE
RADIATOR GRILLE O P E N I N G
(UPPER) HOSE PANEL
THERMOSTAT
HOUSING
RADIATOR
COOLANT
RESERVE
RADIATOR TANK J9200-28
WATER P U M P
Fig. 14 Coolant Recovery Hose (YJ)—Typical
COOLING SYSTEM
RADIATOR-TO- PRESSURE TESTER
WATER P U M P
(LOWER) HOSE L O W E R HOSE
J9200-20
Fig. 12 Radiator Upper & Lower Hoses/Clamps (YJ

4.0L)—Typical
HEATER THERMOSTAT-
TO-HEATER THERMOSTAT
CORE
CORE HOSE HOUSING
Fig. 15 Pressurizing Cooling System—Typical

• the radiator top hose collapses with engine cool-
HEATER
down.
CORE-TO-
WATER P U M P COOLANT FREEZE PROTECTION
HOSE J9200-18
Jeep® cooling systems contain a 50/50 mixture of
anti-freeze and distilled water coolant. This is the
Fig. 13 Heater Hoses/Clamps (YJ)—Typical
recommended coolant mixture for most ambient tem
(5) Inspect the radiator and air-conditioner con peratures. The factory-installed anti-freeze is formu
denser fins for an accumulation of bugs, leaves, de lated to prevent corrosion on all cooling system metal
bris, etc. surfaces.
(6) Test the degree of coolant freeze protection. The degree of coolant freeze protection should be
(7) If necessary, refer to Group 7—Cooling Systems tested every 12 months. If the coolant is contami
for additional information and service procedures. nated or rusty in appearance, cooling system should
be drained and filled with a 50/50 mixture of fresh
RADIATOR CAP coolant.
The radiator cap must be completely tightened to
provide an air-tight seal at the radiator filler neck. ENGINE AIR CLEANER FILTER ELEMENT
The cap vent valve and seat can become contami
nated with coolant sediment, etc. The valve and seat RECOMMENDED MAINTENANCE
should be carefully cleaned if: Engine performance and fuel economy can be af
• the cooling system will not pressurize; fected by a restricted air cleaner filter. The filter
• the coolant recovery bottle coolant level increases should be inspected on a regular basis for excessive
abnormally; and/or air restriction.
(2) Remove the air cleaner filter element from the

BLACK LIGHT
(TOOL 7138)
body/housing (Fig. 17).
CAUTION: Do not tap the filter element or immerse

the filter in liquid to remove trapped particles.
(3) Clean filter element by gently blowing the

trapped particles from the filter with compressed air.
Direct air in the opposite direction of normal intake
air flow. Keep air nozzle at least two inches away
from the filter to avoid damage to filter.
(4) If the filter has become partially saturated with
oil, replace the filter. Test the crankcase ventilating
(CCV) system for proper operation.
(5) Wash the air cleaner cover and body/housing
(Fig. 18) with cleaning solvent and wipe dry.
COVER AIR
INTAKE
DUCT
J9007-25
Fig. 16 "Black Light" Leak Detector— Typical

If the filter element is saturated with oil, replace
the filter element.
FILTER
REQUIRED MAINTENANCE ELEMENT
Engine air cleaner filter must be replaced after

each 48 000-km (30,000-miles).
If a vehicle is frequently operated in "dusty" ar
eas, the air cleaner filter should be inspected often. AIR
CLEANER
FILTER ELEMENT SERVICE/REPLACEMENT HOUSING
(1) Remove the air cleaner cover from the body/
housing (Fig. 17).
COVER CLIP
RETAINER J9200-9
FILTER
ELEMENT
Fig. 18 Air Cleaner Body/Housing & Cover
F R E S H AIR I N L E T
V A C U U M DIAPHRAGM
BLIND RIVET
H E A T E D AIR I N L E T
BODY TOTEMPERATURE
AIR CLEANER n A K W r - ^ SENSOR
C R A N K C A S E
J9000-10 BODY ASSEMBLY
V E N T FILTER 8925-29
Fig. 17 Air Cleaner & Filter Element—2.bL and 4.0L
Engines Fig. 19 Air Cleaner Components-2.5L
(6) Install the air cleaner filter element and attach If a vehicle is used for short trips with frequent,
the cover to the body/housing. extended idle periods, the CCV system could require
more frequent maintenance.
CRANKCASE ¥ENTILAT!ON SYSTEM
All Jeep® engines are equipped with a crankcase SYSTEM OPERATIONAL TEST, INSPECTION
ventilation (CCV) system (Figs. 20 and 21). AND SERVICE
Jeep® engine crankcase ventilation (CCV) systems
tested and inspected for combustion deposits and ser
viced as necessary.
HANDS N E A R T H E D R I V E B E L T ( S ) , P U L L E Y S O R
FAN B L A D E . DO NOT S T A N D IN A D I R E C T L I N E
W I T H T H E FAN B L A D E .
(1) With the engine operating, remove the CCV fit

ting (Fig. 20 or 21).
(2) If the CCV fitting orifice, a "hissing" noise will
be heard as air flows through the orifice. A strong
vacuum force should also be felt when a finger is
placed over the orifice inlet.
Fig. 20 CCV System—2.5L Engine (3) Install the CCV fitting.
(4) Remove end of fresh air hose from air cleaner
and loosely hold a piece of paper next to open end of
hose. Af£er one minute for crankcase vapor pressure
to decrease, paper should be forced against hose
opening.
(5) Turn the engine off. Remove the CCV fitting
and inspect orifice for a restriction.
(6) If the crankcase ventilation system operation is
acceptable no further service is required. If not the
CCV fitting must be cleaned and system operation
tested again.
(7) Refer to items (4) and (5) above. If the re-test
fails after the CCV fitting orifice is cleaned, it will
be necessary to replace the CCV vapor hose and re-
clean the fitting.
(8) Clean or, if necessary, replace the engine air
cleaner filter element. Refer to Engine Air Cleaner
Fig. 21 CCV System—4.0L Engine Filter (above).
SYSTEM OPERATION
FUEL SYSTEM
The 2.5L engine and the 4.0L engine crankcase
ventilation (CCV) systems have a vapor-transfer fit FUEL REQUIREMENTS
ting located on the cylinder head cover. The fitting All Jeep® engines require unleaded gasoline that
has a metered orifice. A molded hose is connected be has a minimum octane rating of 87.
tween the intake manifold and the fitting. In addition, the use of a brand of unleaded gasoline
The air cleaner supplies fresh air to the cylinder that contains detergent, corrosion and stability addi
head cover. The crankcase oil vapor is mixed with tives is recommended.
the fresh air within the cylinder head cover. The
mixture is then forced into the intake manifold. ALCOHOL/GASOLINE BLENDS
Many brands of clean burning, blended unleaded
RECOMMENDED MAINTENANCE gasoline are now available that contribute to cleaner
Crankcase ventilation (CCV) systems should be air. This type of blended fuel is sometimes referred to
tested, inspected and serviced at the same time as as "reformulated gasoline".
the air cleaner filter. When available, the use of this type blended fuel is
recommended.
J L U B R I C A T I O N A N D MAINTENANCE 0 - 21
ETHANOL—Unleaded gasoline and ethanol are

an acceptable blend of fuel that can safely be used
with all Jeep® engines.
MTBE-Unleaded gasoline and MTBE blended fu
els are a mixture of unleaded gasoline and up to 15
percent MTBE (Methyl Tertiary Butyl Ether). Un
leaded gasoline blended with MTBE is acceptable
for use with all Jeep® engines.
ETBE-Unleaded gasoline and ETBE blended fu
els are a mixture of unleaded gasoline and up to 17
percent ETBE (Ethyl Tertiary Butyl Ether). Un
leaded gasoline blended with ETBE is acceptable
for use with all Jeep® engines.
METHANOL—Do not use unleaded gasoline
blended with methanol (wood alcohol) with Jeep® en
gines.
ADDITIVES MIXED WITH GASOLINE

Use of fuel system cleaning additives should be
avoided. Many of the solutions that are intended for
fuel system gum and varnish removal could possibly
contain active solvents. This type of solvent can be Fig. 23 Fuel Filter Replacement—YJ Vehicles
harmful to the gasket and diaphragm material. RECOMMENDED FUEL SYSTEM
REQUIRED FUEL FILTER MAINTENANCE MAINTENANCE
(EXCEPT CALIFORNIA) The general condition of the fuel system should be
The fuel filter (Figs. 22 and 23) must be replaced inspected at the same time as the fuel filter is re
after each 96 000-km (60,000-miles). placed.
The fuel system components (Fig. 24) should be in
BRACKET LEFT spected periodically for fuel leaks and for proper op
eration.
VAPOR FUEL
CANISTER TANK
Fig. 22 Fuel Filter Replacement—XJ Vehicles

RECOMMENDED FUEL FILTER MAINTENANCE
(CALIFORNIA)
A restriction in a fuel filter is usually caused by
contaminants in the fuel. Fuel filter restriction can
reduce engine performance. Fuel filter restriction can
also cause engine starting problems. J9200-13
To avoid potential fuel system malfunction, the

fuel filter (Figs. 22 and 23) should be replaced after Fig. 24 Fuel Hoses & Tubing—Typical
each 96 000-km (60,000-miles).
VACUUM OPERATED, EMISSION CONTROL CYLINDER AIR INTAKE CCV

CCV FITTING
COMPONENTS HEAD «
FITTING
DUCT
COVER
RECOMMENDED MAINTENANCE VENT
TUBE
Emission control components should be tested, in
spected and serviced at the same time the air cleaner
AIR INLET
filter element and/or the fuel filter is replaced. TUBE
The vacuum operated, emission control components
should be inspected for air leaks and for proper oper
ation.
INSPECTION
Inspect the components, hoses, tubing and fittings
for cracks and breaks, and test for correct operation.
If necessary, refer to Group 25—Emission Control
Systems.
CYLINDER CCV INTAKE
HEAD FITTING MANIFOLD
COVER'
AIR
CLEANER J9200-6
Fig. 26 Crankcase Ventilation (CCV)

Components—4.OL Engine
MAP
SENSOR
VACUUM
AIR CLEANER-
TUBE
TO-CANISTER
HOSE
INTAKE
AAANIFOLD
AIR
CLEANER J9200-7
Fig. 25 Crankcase Ventilation (CCV)

Components—2.5L Engine
IGNITION CABLES, DISTRIBUTOR CAP AND
VAPOR
ROTOR CANISTER
AIR
REQUIRED IGNITION SYSTEM MAINTENANCE CLEANER
INTAKE
AAANIFOLD J9200-23
The ignition cables, distributor cap, and rotor must
be replaced after each 96 000-km (60,000-miles). In Fig. 27 Emission Control Components & Hoses/
spect the distributor for excessive wear and replace, Tubing (YJ)—2.5L Engine
as necessary. Refer to Group 8D—Ignition Systems
for additional information. IGNITION TIMING
The ignition timing for 2.5L and 4.0L engines is
RECOMMENDED ROUTINE IGNITION SYSTEM not adjustable. Refer to the specifications listed on
SERVICE { the engine Emission Control Information Label. Re
The ignition cables (Fig. 30) should be kept clean fer to Group 25—Emission Control Systems for addi
and correctly connected at all times. Ensure that the tional information.
cable terminals are firmly seated on the spark plug
nipples and within the distributor and ignition coil
tower wells.
J LUBRICATION AND MAINTENANCE 0 - 23
000-km (30,000-miles). Refer to the Spark Plugs

chart below and to Group 8D—Ignition Systems for
additional information.
SPARK PLUGS
IN61NE PLU© GAP TORQUE
2.5L RC-12LYC 0.88 mm 3 7 N»m

0 . 0 3 5 in 2 7 ft. lbs.
4.0L RC-12LYC 0.88 mm 3 7 N.m

0 . 0 3 5 in 2 7 ft. lbs.
Fig. 28 Emission Control Components & Hoses/

Tubing (XJ)—4.0L Engine
J9200-53
OXYGEN ( 0 ) SENSOR
2
The 0 sensor (Fig. 31) must be replaced after each
2
132 000-km (82,500-miles). The emission-control

maintenance reminder (EMR) lamp will illuminate
SUPPORT
to remind that the 0 sensor must be replaced. Reset
2
BRACKET the emission-control maintenance reminder (EMR)

lamp timer after the sensor has been replaced. Refer
to Group 25—Emission Control Systems for timer re
set and other related information.
Fig. 2 9 Vapor Canister (YJ)—Typical

SPARK SPARK CYLINDER
PLUG PLUG BLOCK
Fig. 30 Ignition System Components (2.5L)—Typical J9200-38

SPARK PLUGS
Fig. 31 0 Sensor—Typical
2
The spark plugs must be replaced after each 48
BATTERY (6) Connect the battery positive cable and then the
negative cable to the battery.
RECOMMENDED MAINTENANCE (7) Apply a small amount of chassis lubricant (or
The battery electrolyte level should be checked and an equivalent protective coating) to the cable termi
the cable clamps should be inspected for corrosion. nals to minimize corrosion.
This should be done when the oil is changed and the
oil filter is replaced. RUBBER AND PLASTIC DUCTS/HOSES/TUBING
The battery cables should be inspected for abnor
mal clamp and battery terminal post corrosion. Ser
vice the terminals and cable clamps as necessary. Rubber and plastic ducts/hoses/tubing should be in
In addition, the general condition of the battery spected at the same time the engine oil is changed
and the oil filter is replaced.
should be determined before the start of cold and hot
The conditions associated with vehicle operation
weather seasons. If the battery condition is marginal
determines the usable life of the rubber and plastic
or worse, it should be replaced.
ducts/hoses/tubing. These conditions include:
Care should be taken when disposing a bat • the extent and quality of vehicle maintenance,
tery after removal from a vehicle. Lead-acid bat • the geographic area of vehicle operation, and
teries are highly poisonous and, when disposed, • the length of exposure time to excess heat and
could create a problem for the environment. chemical contaminants.
INSPECTION/SERVICE
DUCT/HOSE/TUBING INSPECTION-EXCEPT
EMISSION CONTROL HOSES/TUBING
WARNING; W E A R S A F E T Y G L A S S E S , R U B B E R
Refer to Group 25—Emission Control Systems.
G L O V E S AND P R O T E C T I V E CLOTHING W H E N HAN
Engine performance could be affected by air leaks
DLING/SERVICING A B A T T E R Y . T H E B A T T E R Y
into various hoses.
E L E C T R O L Y T E CONTAINS S U L F U R I C ACID AND
W I L L C A U S E HARM I F I T C O N T A C T S S K I N , E Y E S
OR CLOTHING. I T W I L L A L S O DAMAGE P A I N T E D
(AS W E L L A S UN-PAINTED) S U R F A C E S OF A VEHI
C L E . I F S U L F U R I C ACID C O N T A C T S ANY O F
THESE, F L U S H IMMEDIATELY WITH LARGE
A M O U N T S O F W A T E R . I F S U L F U R I C ACID CON
T A C T S S K I N O R E Y E S , G E T IMMEDIATE MEDICAL
A T T E N T I O N . DO NOT S M O K E IN T H E VICINITY O F
A B A T T E R Y . K E E P O P E N F L A M E S AND S P A R K S
AWAY FROM B A T T E R Y F I L L E R C A P S B E C A U S E
E X P L O S I V E GAS I S A L W A Y S P R E S E N T .
(1) Disconnect the battery negative cable and then

the positive cable.
(2) Clean the battery cable clamps and terminal
posts with a wire brush and a battery terminal CYLINDER J9200-2
cleaner.
(3) Pry the battery cell filler caps upward to re Fig. 32 Brake Booster Vacuum Hose (XJ)—Typical
move them and inspect each filler well. It could pos Rubber/plastic ducts, hoses and tubing should
sibly be necessary to loosen the battery holddown be replaced immediately if there is any evidence
clamp to remove the caps. Maintain the electrolyte of deterioration.
level above the battery plates and at the bottom of (1) Inspect all hose fittings for looseness and corro
the filler well ring. Add distilled water or low-min sion. Inspect rubber ducts (Fig. 33) and hoses for
eral content drinking water, if necessary. In freezing brittleness and cracks. Examine the hose ends (those
weather (below 0°C/32°F), add the water just before that are slipped over nipple connectors) for splits.
driving to ensure that it mixes thoroughly with the (2) Inspect surface of hoses and tubing (Fig. 34) for
electrolyte. This will prevent it from freezing. heat and mechanical damage. The hose and tubing
(4) Remove the battery holddown strap and clean that is located near an exhaust manifold should
the battery case/battery tray.Clean with bicarbonate be given special attention.
of soda (baking soda) and water. Rinse and dry the (3) Inspect the rubber hose routing to ensure that
battery case/tray thoroughly after cleaning. the hoses do not contact any heat source, moving
(5) Position the battery in the tray and install the component, etc., that could potentially cause heat or
holddown strap. Do not over-tighten the nuts. mechanical damage.
AIR ATF RADIATOR ENGINE

ENGINE
DUCT COOLER
AIR
CLEANER
RETURN S RETURN
HOSE HOSE
(TO AUX. (FROM AUX.
J9200-30 COOLER) COOLER) J9200-40
Fig. 33 intake Air Duct (XJ)—Typical Fig. 36 ATF Cooler/Auxiliary Cooler Hoses
(4.0L)-XJ Vehicles
REAR
WASHER FLUID RADIATOR
TUBE
WASHER ATF
FLUID RETURN
RESERVOIR HOSE
LEFT
FRONT
FENDER
DASH
PANEL
ATF
COOLER
FRONT
FITTING
WASHER
CONVOLUTED
FLUID
TUBE J9200-1
TUBE
ATF
SUPPLY
Fig. 34 Washer Fluid Tubing—Typical HOSE
(4) Inspect all the hose connections to ensure that
they are secure and that there is no fluid leakage. In
many instances, liquid lubricants are used to aid in
the connection of hoses to couplings. J9200-41
ATF RADIATOR
COOLER
Fig. 37 ATF Cooler Hoses (4.0L)-YJ Vehicles
ENGINE SUPPORTS
The general condition of the engine supports
ENGINE should be inspected at the same time as the engine
oil is changed and the oil filter is replaced.
INSPECTION
(1) Test the hardware that attaches the engine cyl
inder block to the engine support brackets (Figs. 38
and 39) for the specified tightening torque.
FLUID (2) Inspect the rubber in the engine support cush
ions (Figs. 38 and 39) for softening and swelling.
Slight surface deterioration and wear at the ends
Fig. 35 ATF Cooler Hoses —XJ Vehicles will not affect the functioning of an engine support.
Fig. 38 Front Engine Support—Typical

TRANSMISSION
Fig. 40 Drive Belts-XJ/YJ Vehicles

INSPECTION
When inspecting an exhaust system, inspect for
cracked or loose joints, stripped screw/bolt threads,
corrosion damage, and worn or broken hangers. Re
place all components that are corroded or damaged.
Do not attempt repair. Also, inspect for the following
obvious conditions and correct as necessary:
SUPPORTED • exhaust system leaks, damage, misalignment;
BY F R A M E
CROSSMEMBER J9200-15 • contact with body panels metal or the frame; and
• catalytic converter "bulging" or excessive heat
Fig. 39 Rear Engine Support—Typical damage.
DRIVE BELT CAUTION: A catalytic converter will become con
taminated if leaded gasoline i s burned in the en
gine. If t h i s occurs, the complete converter must be
The drive belt (Fig. 40) should be inspected for
replaced.
cracks, fraying, and excessive wear. If necessary, re
fer to Group 7—Cooling Systems for replacement pro
cedures and adjustment specifications. AIR-CONDITIONER COMPRESSOR/HOSES/
FITTINGS
The drive belt (Fig. 40) must be adjusted after each RECOMMENDED MAINTENANCE
48 000-km (30,000-miles) interval of vehicle opera The general condition of the A/C compressor, hoses
tion has elapsed. The drive belt must be replaced af and fittings should be inspected at the same time as
ter each 96 000-km (60,000-miles). If necessary, refer the engine oil is changed.
to Group 7—Cooling Systems.
LUBRICANT AND REFRIGERANT
EXHAUST SYSTEM In addition to inspection, the lubricant level in the
compressor (Fig. 44) should be determined if there
REQUIRED MAINTENANCE ) are indications that oil was lost.
The general condition of the exhaust system must Loss of lubricating oil usually accompanies a loss of
be inspected after each 12 000-km (7,500-miles). refrigerant. The presence of bubbles/white foam
An exhaust system must be properly aligned to within the receiver/drier sight glass indicates that
prevent stress, leakage, and vehicle body contact. some loss of refrigerant has occurred.
*l L U B R I C A T I O N AND M A I N T E N A N C E 0 - 27
Fig. 42 A/C System (XJ)-4.0L Engine Fig. 44 A/C Compressor-Typical

For additional information involving the A/C sys
tem, refer to Group 24—Heater And Air Condition
ing.
DRiWETRAlN
INDEX
page page
Automatic Transmission . . . . . . . . . . . . . . . . . . . . 29 Manual Transmission . . . . . . . . . . . . . . . . . . . . . . 28
Drive Shafts 33 Rubber and Plastic Hoses/Tubing . . . . . . . . . . . . 34
Front and Rear Axles . 32 Transfer Case 31
Hydraulic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 28
HYDRAULIC CLUTCH relation to the level indicator ring (Fig. 3) located in
side the reservoir. If necessary, add fluid until the
RECOMMENDED MAINTENANCE height is level with the indicator ring.
Check fluid level in the hydraulic clutch master
RESERVOIR
cylinder reservoir (Fig. 1) at the same time engine CAP
oil is changed and oil filter is replaced. Add fluid as
necessary.
CLUTCH FLUID DASH
CYLINDER RESERVOIR LINE
Fig. 2 Hydraulic Clutch Master Cylinder Fluid

Reservoir
ENGINE
Fig. 1 Hydraulic Clutch (YJ)-Typical

FLUID SPECIFICATION
The only fluid recommended for use in a hydraulic
clutch system is MOPAR Brake And Hydraulic
Clutch Fluid., or an equivalent fluid.
RING
CAUTION: Never use reclaimed brake fluid or fluid J9106-11
from an unsealed container. In addition, do not use
fluid from a container that has been opened and al Fig. 3 Hydraulic Clutch Fluid Level
lowed to stand for an extended length of time.
Moisture in the air can be absorbed by the fluid, MANUAL TRANSMISSION
which cause dilution with loss of effectiveness. RECOMMENDED MAINTENANCE
The lube oil level in manual transmissions should
FLUID LEVEL be determined at the same time as the engine oil is
Remove the master cylinder fluid reservoir cap changed and the oil filter is replaced. Add lube oil as
(Fig. 2). The fluid level is determined by its height in necessary.
Under normal driving conditions, manual trans (4) Remove the drain-hole plug and drain the lube
mission lube oil should be changed after each 60 oil from the transmission into the container.
000-km (37,500-miles). With severe driving condi Care should be exercised when disposing used
tions, after each 29 000-km (18,000-miles). lube oil after it has been drained from a trans
mission.
LUBRICANT SPECIFICATION (5) Install the drain-hole plug in the transmission.
When it becomes necessary to add to or change the Tighten the plug with 37 N«m (27 ft. lbs.) torque.
lube oil in a Jeep® manual transmission, use SAE (6) Fill the transmission until the lube oil begins
75W-90, API Quality Grade GL-5 gear lubricant. to drip out of the fill hole with SAE 75W-90, API
Quality Grade GL-5 gear lubricant.
LUBRICANT LEVEL (7) Install the fill-hole plug in the transmission.
The fill-hole plug for all manual transmissions are Tighten the plug with 37 N*m (27 ft. lbs.) torque.
located on the right side of the case (Fig. 4). Deter (8) Remove the support and lower the vehicle.
mine the lubricant level according to the following
procedure. AUTOMATIC TRANSMISSION
FILL HOLE P L U G
Check fluid level in automatic transmissions (Fig.
5) the same time the engine oil is changed and the
oil filter is replaced. Add ATF as necessary.
AW-4
EXTENSION
AUTOMATIC
HOUSING
TRANSMISSION
M A N U A L TRANSMISSION DRAIN HOLE PLUG J9100-1
Fig. 4 Manual Transmission Fill- & Drain-Hole

Plugs—Typical
(1) Remove the fill-hole plug (Fig. 4) from the
transmission. The lube oil should be level with the PAN J9200-49
bottom edge of the fill hole. The level can be slightly

below the bottom edge of the fill hole if the lube oil Fig. 5 AW-4 Automatic Transmission (XJ)
is cold. Under normal driving conditions, the ATF should
If the transmission is warm, lube oil could drip be changed and the filter replaced after each 48
out of the fill hole. This is acceptable but the 000-km (30,000-miles). With severe driving condi
lube oil should not "gush out" of the fill hole. tions, after each 29 000-km (12,000-miles).
(2) If not acceptable, raise the lube oil level to the
bottom edge of the transmission fill hole. Use SAE ATF SPECIFICATIONS
75W-90, API Quality Grade GL-5 gear lubricant. When it becomes necessary to add fluid (ATF) to a
Add lube oil in small amounts to raise the Jeep® automatic transmission (or when the ATF is
level. replaced), use:
(3) Install the fill-hole plug in the transmission. • Mercon™ ATF only for AW-4 automatic transmis
Tighten the plug with 37 N«m (27 ft. lbs.) torque. sions (XJ vehicles), and
• MOPAR ATF PLUS (or an equivalent Mercon™/
LUBE OIL CHANGE
Dexron II™ ATF) for 999 automatic transmissions
When it becomes necessary to change manual
transmission lube oil, use the following procedure. (YJ vehicles).
SPECIAL ADDITIVES
(2) Remove the fill-hole plug from the transmis
sion. The addition of any special-type fluid to a Jeep®
(3) Place a container to collect the lube oil under automatic transmission is not recommended. The
the transmission drain-hole plug. only exception is the addition of black-light detection
0 - 30 L U B R I C A T I O N AND MAINTENANCE
J
dye to aid in detecting the source of ATF leaks. The DIPSTICK
use of transmission sealing additives should also be
avoided.
Black-light detection dye is factory-installed in
automatic transmissions and, unless the A T F
has been drained and re-placed, it is not neces
sary to add dye.
ATF LEWEL
Determine the ATF level according to the following
procedure.
HANDS N E A R T H E D R I V E B E L T , P U L L E Y S O R F A N
B L A D E . DO NOT S T A N D IN A D I R E C T L I N E W I T H
T H E FAN B L A D E .
(1) Operate the engine and allow the automatic

transmission sufficient time to warm to the normal
operating temperature (77°C/170°F).
When at normal operating temperature, A T F
will be uncomfortable to fingertips when the Fig. 6 Dipstick & ATF Level—Typical
dipstick is touched. Normally, 25 km (15 miles) is
D E T E R M I N E T H E A T F LEVEL W I T H T H E
a sufficient driving distance for a transmission
VEHICLE LEVEL, T H E T R A N S M I S S I O N I N N E U T R A L
to warm to normal operating temperature (77°C/ A N D T H E FLUID TEMPERATURE ABOVE 22°C
170°F).
(2) Place the vehicle on a level surface.
(3) Operate the engine at idle speed.
(4) Engage the parking brake.
=CADD| | FULL CHECK
(5) Place a block in front of and at the rear of one
wheel/tire to prevent vehicle movement. 17/8 hs— U l i n * »
(6) Depress the brake pedal and move the trans UNSAFE—*
mission selector lever through all the positions and
then place the selector lever in NEUTRAL position.
(7) Remove the dipstick (Fig. 6) from the transmis T H E VEHICLE S H O U L D N O T BE D R I V E N
sion filler tube and wipe it clean. IF T H E A T F LEVEL IS L O W E R T H A N
(8) Insert the dipstick into the transmission filler 7 / 8 INCH B E L O W T H E A D D M A R K O R M O R E
T H A N 1 INCH A B O V E T H E F U L L M A R K . J9200-10
tube and "seat" the cap on top of the tube.
(9) Remove the dipstick and observe the ATF level Fig. 7 Safe ATF Level Above 22°C/72°F
on both sides of the dipstick. The ATF level is accept
able when it is between the ADD and FULL marks. (Figs. 6 and 7). It requires only 0.5 liter (1.0 pint)
(10) While determining the ATF level in a trans of ATF to raise the level from the ADD mark to
mission, also note the general condition of the fluid. the FULL mark.
Examine the fluid closely. If doubtful about its con (13) Inspect for ATF leaks and correct as neces
dition, drain a sample into a small container for sary.
evaluation. (14) Remove the wheel/tire blocks.
(11) If the ATF level is either at or below the ADD
mark, add sufficient ATF to raise the level to the ATF AND FILTER CHANGE
FULL mark on the dipstick (Figs. 6 and 7). Automatic transmission fluid (ATF) does not dete
riorate or wear out, but it does become contaminated.
CAUTION: Do not over-fill an automatic transmis These contaminates will eventually restrict passages
sion (Fig. 7). Over-filling can cause the A T F to and orifices. The result is hard or rough shifting, or
foam, which will result in over-heating, fluid oxida complete transmission failure. Also, the varnish
tion and varnish formation. eventually causes rubber seals to harden and become
brittle.
(12) When it is necessary to add ATF, insert a
long-necked funnel into the transmission filler tube
J L U B R I C A T I O N A N D MAINTENANCE 0 - 31
When it is necessary to change the ATF and re brake. Move the transmission selector lever through
place the filter in a Jeep® automatic transmission, all positions, then place the selector lever in NEU
use the following procedures. TRAL position.
(8) With the transmission at normal operating
DRAINING ATF/FILTER RE10WAL temperature, observe the ATF level on the dipstick
Drain the automatic transmission fluid (ATF) im (Fig. 6). Add ATF (if necessary) to raise the level to
mediately after stopping the engine (before the ATF the FULL mark on the dipstick. Only 0.5 liter (1.0
cools). pint) will raise the level from the ADD mark to
(1) Raise and support the vehicle. the FULL mark when the ATF is at normal op
(2) Loosen the transmission pan bolts and drain erating temperature.
the original ATF into an appropriate container. Re
(9) Inspect for fluid leaks and correct as necessary.
move the pan bolts, the pan and the gasket.
(10) Remove the wheel/tire blocks.
Care should be exercised when disposing
9
"used' ATF after it has been drained from a ve
TRANSFER CASE
hicle transmission.
(3) Remove the screws and the ATF filter (Fig. 8). RECOMMENDED MAINTENANCE
Discard the filter. The fluid (ATF) level in transfer cases should be
OIL OIL FILTER determined at the same time as the engine oil is
FILTER SCREWS changed and the oil filter is replaced. Add ATF as
necessary.
In addition, transfer case ATF should be changed
after each 48 000-km (30,000-miles) interval of vehi
cle operation has elapsed.
FLUID SPECIFICATIONS
If it is necessary to add fluid to a transfer case (or
when the fluid is changed), use MOPAR ATF PLUS
or an equivalent Mercon™/Dexron II™ ATF.
FLUID LEVEL
The transfer case fill-hole plug is located at the
rear of the housing (Fig. 9).
FILL HOLE
PLUG
J9000-17
Fig. 8 ATF Filter-Typical

FILTER INSTALLATION/ATF R E - F I L L
(1) Install a replacement ATF filter (Fig. 8).
Tighten the screws with 4 N»m (35 in. lbs.) torque.
(2) Clean the pan thoroughly. Install a replace
ment gasket on the pan. Install the pan with the at
taching bolts:
• model AW-4 transmission — tighten the pan bolts
with 7 N*m (60 in. lbs.) torque; and
• model 999 transmission — tighten the pan bolts
DRAIN HOLE
with 17 N-m (150 in. lbs.) torque. PLUG J9100-5
(3) Remove the support and lower the vehicle.
(4) Pour approximately 4.7 liters (5 quarts) of ATF Fig. 9 Transfer Case—Typical
into the filler tube. Use Mercon™ ATF for AW-4 au
tomatic transmissions. Use MOPAR ATF PLUS or Determine the transfer case fluid (ATF) level ac
equivalent, for 999 automatic transmissions. cording to the following procedure.
(5) Place a block in front of and at the rear of one (1) Raise and support the vehicle.
wheel/tire to prevent vehicle movement. (2) Remove the fill-hole plug from the transfer
(6) Start the engine and allow it to idle a few min case. The ATF level should be at the bottom edge of
utes. the fill hole. The level can be slightly below the bot
(7) Apply the brake pedal and engage the parking tom edge of the fill hole if the fluid is cold.
0 - 32 LUBRICATION A N i MAINTENANCE J
If the transfer case A T F is warm, it is accept lubricant in the rear axle. XJ Vehicles equipped
able for the fluid to drip out of the fill hole. If with a class I I I trailer hitch require SAE
the fluid "gushes" out of the fill hole, the level is 75W-140 synthetic gear lubricant in the rear
too high. axle.
(3) If the level is low, raise it to the bottom edge of
the fill hole with MOPAR ATF PLUS or an equiva LUBRICANT LEVEL
lent Mercon™/Dexron II™ ATF. Determine the axle differential housing lubricant
(4) Install the fill-hole plug. Tighten the plug with level according to the following procedure.
47 N*m (35 ft. lbs.) torque. (1) Raise and support the vehicle.
(5) Remove the support and lower the vehicle. (2) Remove the fill-hole plug (Figs. 10 and 11)
from the axle differential housing cover. The gear lu
FLUID CHANGE bricant should be 13 mm (1/2 inch) below the bottom
When it becomes necessary to change the ATF in a edge of the fill hole.
Jeep® transfer case, use the following procedure. DIFFERENTIAL
(1) Raise and support the vehicle. HOUSING
(2) Remove the fill-hole plug from the transfer
case.
(3) Place an appropriate container under the trans
fer case drain-hole plug.
(4) Remove the drain-hole plug and drain the ATF
from the transfer case into the container.
Care should be exercised when disposing
"used" A T F after it has been drained from a
transfer case.
CAUTION: Do not over-tighten the drain and fill-hole

plugs. Over-tightening can strip the hole threads
and/or crack the aluminum housing.
(5) Install the drain-hole plug in the transfer case.

Tighten the plug with 47 NTH (35 ft. lbs.) torque.
(6) Fill the transfer case to the bottom edge of the
fill hole with MOPAR ATF PLUS (or an equivalent
Mercon™/Dexron II™ ATF).
(7) Install the fill-hole plug in the transfer case.
Tighten the plug with 47 NTH (35 ft. lbs.) torque.
(8) Remove the support and lower the vehicle.
FRONT AND REAR AXLES
The lubricant level in axle differential housings
should be determined at the same time as the engine
oil is changed and the oil filter is replaced. Add lu
bricant as necessary.
In addition, with normal driving conditions, the
axle lubricant should be changed after each 48
000-km (30,000-miles). With severe driving condi Fig. 11 Front Axle (4WD)—Typical
tions, after each 29 000-km (12,000-miles).
(3) If not acceptable, raise the lubricant level to 13
LUBRICANT SPECIFICATIONS mm (1/2 inch) below the bottom edge of the fill hole.
For normal vehicle operation, use SAE 75W-90, Add lubricant in small amounts to raise the
API Quality Grade GL-5 gear lubricant in all Jeep® level.
front (4WD only) and rear axles. Vehicles equipped (4) Install the fill-hole plug in the differential
with a Trac-Loc rear axle also require a friction mod housing cover. Tighten the plug with 34 N°m (25 ft.
ifier additive with the gear lubricant. lbs.) torque.
When involved in trailer towing applications (5) Remove the support and lower the vehicle.
use SAE 80W^140, A P I Quality Grade GL-5 gear
LUBRICANT CHANGE DIFFERENTIAL

When it becomes necessary to change the axle lu HOUSING
bricant in a Jeep® front or rear axle, use the follow

ing procedure.
(2) Place a container under the axle differential
housing.
(3) Remove the axle differential housing cover
bolts. Remove the housing cover.
(4) Allow the axle gear lubricant to completely
drain into the container.
CAUTION: Do not flush a rear axle Trac-Loc differ

ential. Trac-Loc differentials may be cleaned only
by disassembling the unit and wiping the compo
nents with clean, lint-free cloth.
Fig. 13 Differential Housing Cover Installed
(5) Flush the inside of the differential housing
(9) Remove the fill-hole plug and add the replace
with a flushing oil. Do not use water, steam, ker
osene or gasoline for flushing. ment gear lubricant to the differential housing. Refer
(6) Remove any residual RTV sealant/gasket mate to Specifications above.
rial from the differential housing and cover. Thor (10) Install the fill-hole plug. Tighten the plug
oughly clean the contact surfaces with mineral with 34 N°m (25 ft. lbs.) torque.
spirits and dry the surfaces completely. (11) Remove the support and lower the vehicle.
(7) Apply a "bead" of MOPAR RTV Sealant, or an
equivalent sealant, around the bolt circle on the DRIVE SHAFTS
housing and on the cover (Fig. 12).
RECOMMENDED LUBRICATION
SEALANT With normal driving conditions, the drive shaft
U-joint couplers and slip yoke splines (Figs. 14 and
15) should be lubricated after each 12 000-km (7,500-
miles). With severe driving conditions, after each 4
800-km (3,000-miles).
FRONT REAR U-JOINT TRANSFER
(TYPICAL) J9003-85
Fig. 12 RTV Sealant Application—Typical

If differential housing cover is not installed
within 20 minutes after applying sealant, the
sealant must be removed and another "bead" SLIP YOKE J9200-37
applied.
(8) Install the cover on the differential housing Fig. 14 Front Drive Shaft (4WD)—Typical
with the attaching bolts (Fig. 13). Tighten the cover
bolts with 47 N-m (35 ft. lbs.) torque.
FRONT DRIVE REAR YOKE REAR • the extent and quality of vehicle maintenance,
• the geographic area of vehicle operation, and
• the length of exposure time to excess heat and
chemical contaminants.
CASE
Fig. 15 Rear Drive Shaft (4WD)—Typical

CAUTION: It i s very important that drive shafts be
lubricated at periodic intervals and that the speci
fied type of lubricant be used. Failure to properly
lubricate could result in premature wear of drive
shaft components.
LUBRICATION FITTINGS
The drive shaft universal-joint couplers (U-joints)
and the front drive shaft slip yoke splines are
equipped with "Zerk" fittings. The (CV-joints) are lu Fig. 16 Front Axle Went Hose (4WD)-XJ Vehicles
bricated when assembled during manufacture and do
not require additional lubrication.
LUBRICANT SPECIFICATION
Drive shaft U-joint couplers and slip yoke splines
should be lubricated with a lubricant that is identi
fied as NLGI GC-LB lubricant.
SLIP-YOKE SPLINE LUBRICATION

The method below will ensure complete lubrication
of the front drive shaft slip-yoke splines (Fig. 14).
(1) Clean the tips of the "Zerk" type fittings.
(2) Use a gun or another appropriate lubricant dis VENT
HOSE
penser to force pressurized lubricant into the slip
yoke "Zerk" fittings.
(3) When the lubricant appears, cover the pressure
relief hole with a finger. Force pressurized lubricant
into fitting until it appears at slip-yoke seal.
RAIL FRONT
RUBBER AND PLASTIC HOSES/TUBING AXLE
The condition of underbody rubber hose and plastic Fig. 17 Front Axle Vent Hose—YJ Vehicles
tubing should be inspected for failure at the same
time as oil is changed and oil filter is replaced. (1) Inspect all hose and tubing fittings for loose
ness and corrosion. Inspect the rubber hoses for brit-
HOSE/TUBING INSPECTION tleness and cracks. Thoroughly inspect the hose ends
Vehicle operating conditions determine the useable (those that are slipped over nipple connectors) for
life of underbody hoses and tubing. These conditions splits.
include:
DASH VACUUM TRANSFER VENT V E N T CAP

PANEL TUBE AND CASE HOSE
WIRE HARNESS
VENT HOSE AND

VACUUM BRAKE T U B E T E E
TUBE
WIRE REAR
CONNECTOR AXLE
VACUUM
TUBE
CONNECTOR
WIRE
HARNESS
CONNECTOR
VACUUM
SHIFT MOTOR
AXLE
VACUUM
J9200-29 J9200-44
SHIFT MOTOR
Fig. 18 Front Axle Vacuum Shift Tubing Fig. 21 Rear Axle Vent Hose—YJ Vehicles
ENGINE
VENT
HOSE
TRANSFER
CASE
QUARTER
PANEL REAR AXLE
VENT
HOSE
TRANSMISSION J920042 WHEELHOUSE J9200-45
Fig. 19 Transfer Case Vent Hose (4WD)—Typical Fig. 22 Rear Axle Vent Hose At Wheelhouse— YJ
VENT VENT VENT FRAME
Vehicles
HOSE HOSE RAIL (2) Inspect the surface of hoses and tubing for heat
and mechanical damage. Hose and tubing located
close to an exhaust pipe should be given special at
tention.
(3) Inspect the rubber hose routing to ensure that
the hoses do not contact any heat source, moving
component, etc., that would potentially cause heat or
mechanical damage.
(4) Inspect all the hose connections to ensure that
they are secure and there is no fluid leakage. Actual
dripping of hot fluid should be noted and the clamps
VENT HOSE AXLE
tightened in an attempt to stop the leakage before
A N D BRAKE SHAFT replacing the hose.
J920043
TUBE TEE TUBE
Fig. 20 Rear Axle Vent Hose—XJ Vehicles

0 - 36 L U B R I C A T I O N AND MAINTENANCE J
CHASSIS AND BODY COMPONENTS
INDEX
page page
Body Components 40 Manual Steering Gear—YJ Vehicles 38
Chassis Component and Wheel Bearing Power Brake System 38
Lubricants 36 Power Steering System 37
Front Wheel Bearings 37 Steering Linkage and Ball Studs 36
Headlamps 41 Tires 40
C H A S S I S COMPONENT AND W H E E L BEARING STEERING LUBRICATE LUBRICATE LUBRICATE

KNUCKLE
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.
N A T I O N A L LUBRICATING
GREASE INSTITUTE
-CERTIFICATION
SYMBOL
NLGI
AUTOMOTIVE
LUBRICATE
LUBRICATE
WHEEL BEARING & CHASSIS DRAG PITMAN

LUBRICANT LINK TIE ROD ARM YOKE J9200-33
USAGE A N D Fig. 2 Steering Components (XJ)—Typical

GC-LB QUALITY D E S I G N A T I O N
LUBRICANT SPECIFICATION
Steering linkage should be lubricated with a dual-
purpose, lithium-base lubricant that is identified as
J9200-57 NLGI GC-LB lubricant.
Fig. 1 NLGI Lubricant Container Certification/ INSPECTION/LUBRICA TION
Identification Symbol (1) Inspect the steering linkage. Examine the tie
The letter G designates wheel bearing lubricant. rods and the drag link for bending, and the ball
Letter L designates chassis lubricant. When the let studs for looseness and excessive wear.
ters are combined the lubricant can be used for dual (2) Replace, as necessary, all torn/ruptured ball-
applications. The suffix letters C and B designate the stud seals and damaged/defective steering linkage
level of the lubricant for the application. The letter C components.
represents level available for wheel bearing lubricant
(G) and the letter B represents level available for CAUTION: Use care to prevent lubricant from con
chassis lubricant (L). tacting the brake rotors.
STEERING LINKAGE AND BALL STUDS (3) Lubricate the ball studs:
• clean the tips of the "Zerk" type lubrication fit
RECOMMENDED MAINTENANCE tings on the tie-rod and drag-link ball-stud ends to
The general condition of the steering linkage (Fig. avoid lubricant contamination;
2) should be inspected and the ball studs should be • lubricate the ball studs with high quality, dual-
lubricated: purpose, lithium base chassis/wheel bearing lubri
® 2WD vehicles - after each 24 000-km (15,000- cant (NLGI GC-LB lubricant);
miles) or six-months interval of vehicle operation has • cease the lubricant pressure when lubricant begins
elapsed; or to freely exit the base of the seal, or if the seal be
• 4WD vehicles - after each 12 000-km (7,500- gins to expand; and
miles) or six-months interval of vehicle operation has • wipe the excess lubricant from the exterior sur
elapsed. faces of the ball joints and the adjacent surfaces.
FRONT WHEEL BEARINGS ing and bearing damage. Also, excessive lubricant
Only 2WD XJ vehicles are equipped with front can be forced out of the wheel hub cavity and con
wheel bearings. XJ vehicles have semi-floating axle taminate the brake rotor/pads.
shafts and axle shaft bearings that are lubricated via
differential lube oil. (8) Partially fill the wheel hub cavity with chassis/
wheel bearing lubricant (NLGI GC-LB lubricant).
RECOMMENDED MAINTENANCE—2WD X J (9) "Pack" the wheel bearings with chassis/wheel
VEHICLES bearing lubricant (NLGI GC-LB lubricant). Ensure
The front wheel bearings should be lubricated ("re that sufficient lubricant is forced between the bear
packed") at the same time as front brake pad/caliper ing rollers.
service is conducted. (10) Install the wheel inner bearing in the wheel
hub and install a replacement seal.
LUBRICANT SPECIFICATION (11) Clean the disc brake rotor contact surfaces, if
Wheel bearings should be lubricated with a lubri necessary.
cant that is identified as NLGI GC-LB lubricant. (12) Install the wheel hub/disc brake rotor on the
spindle.
INSPECTION/LUBRICA TION (13) Install the wheel outer bearing, the thrust
(1) Remove the wheel/tire and the disc brake cali washer, and the spindle nut.
per. Do not disconnect the caliper brake fluid (14) Tighten the spindle nut with 28 N«m (21 ft.
hose unless the caliper must also be removed for lbs.) torque while rotating the disc brake rotor to
maintenance. Support the caliper with a hanger "seat" the bearings.
to prevent brake fluid hose damage.
(15) Loosen the spindle nut 1/2 turn. While rotat
(2) Remove the dust cap, the cotter pin, the nut re ing the disc brake rotor, tighten the spindle nut with
tainer, the adjustment nut, and the thrust washer 2 N»m (19 in. lbs.) torque.
from the spindle (Fig. 3). Discard the cotter pin. (16) Install the nut retainer and a replacement cot
OUTER THRUST NUT ter pin.
WHEEL WASHER RETAINER (17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface. Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.
POWER STEERING SYSTEM

The condition of power steering system should be
inspected and the fluid level checked. Add fluid as
necessary.
FLUID SPECIFICATION
Jeep® power steering systems require MOPAR
Power Steering Fluid, or an equivalent product.
Fig. 3 2WD Front Wheel Bearings—XJ Vehicles
The original power steering fluid installed in
(3) Remove the wheel outer bearing from the hub. Jeep® vehicles includes "black-light" leak detec
(4) Remove the wheel hub/disc brake rotor from tion dye.
the spindle.
(5) Remove the seal and the inner wheel bearing INSPECTION
from the hub cavity. Inspect the power steering system (Figs. 4 and 5)
(6) After removal, inspect both front wheel bearing for the sources of fluid leaks, steering gear housing
races for indications of "pitting", "brinelling" and ex cracks and ensure that the steering gear is securely
cessive heat. attached to the vehicle frame rail. Inspect the steer
(7) Wipe the spindle clean and apply a small ing damper for leaks and loose connections.
amount of chassis/wheel bearing lubricant (NLGI
GC-LB lubricant) to prevent rust. Wipe the wheel FLUID LEVEL
hub cavity clean. The fluid level dipstick is attached to the reservoir
cap (Fig. 6). The fluid level in the reservoir can be
CAUTION: Do not over-fill the wheel hub cavity with determined with the fluid either hot or cold.
lubricant. Excessive lubricant can cause overheat (1) Remove the cap from the reservoir.
ENGINE POWER
STEERING
PUMP
FLUID
PRESSURE
HOSE
FLUID
RETURN
HOSE
STEERING RESERVOIR
GEAR CAP W I T H
DIPSTICK
J8900-27
J9200-3 Fig. 6 Power Steering Fluid Reservoir

Dipstick— Typical
Fig. 4 Power Steering System—XJ Vehicles
essary (refer to Group 19—Steering for additional in
POWER formation and service procedures).
RESERVOIR STEERING
PUMP
POWER BRAKE SYSTEM
RESERVOIR-TO-
P U M P HOSE
The condition of the brake system should be in
spected and the fluid level in the master cylinder
should be checked each time the brake system is ser
viced. Add brake fluid and repair as necessary.
In addition, the brake system should be operation
ally tested periodically to ensure that it is function
ing normally.
FLUID SPECIFICATION
Jeep® power brake systems require MOPAR
Heavy-Duty Brake Fluid, or an equivalent product
identified as conforming to FMVSS No. 116, DOT-3
and SAE J-1703 specifications.
RESERVOIR-TO-
HIGH PRESSURE
Use fresh brake fluid only when adding fluid to
GEAR HOSE
HOSE the reservoir, to fill the brake system. Never use re
claimed fluid,
J9200-22
BRAKE FLUID LEVEL

Fig. 5 Power Steering System—YJ Vehicles
(2) Depending on fluid temperature, if the level is STANDARD POWER BRAKE SYSTEM
below the FULL HOT mark or the FULL COLD (1) Clean the cover and the sides of the brake fluid
mark on the dipstick, add power steering fluid. reservoir.
(3) Install the cap on the reservoir. (2) Detach the bail retainer from the reservoir
cover and remove the cover from the reservoir.
MANUAL STEERING GEAR—YJ VEHICLES (3) The brake fluid level should be 6 mm (1/4 in)
below the rim of each reservoir well for XJ and YJ
RECOMMENDED MAINTENANCE Vehicles (Fig. 7). If not, add brake fluid as necessary.
The manual steering gear should be inspected for (4) Inspect the reservoir cover bail retainer for ten
damage at the same time as the engine oil is sion and the cover for proper fit. The cover should fit
changed and the oil filter is replaced. Repair as nec- tight and have a good seal.
FLUID COVER
Fig. 7 Reservoir Fluid Level—Typical Fig. 8 Reservoir Fluid Level—Anti-Lock Brake

(5) Inspect the reservoir rubber diaphragm seal for System
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE S Y S T E M - X J VEHICLES

The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow

and possible reservoir damage when the pump mo
tor energizes.
(3) The brake fluid level should be no lower than

the MIN arrow indicator on the side of the reservoir J9200-12
(Fig. 8). If not, add brake fluid as necessary. Raise
the fluid level to the MAX arrow indicator only. Do Fig. 9 Rubber Brake Fluid Hose—Typical
not over-fill the reservoir. (1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(4) Turn the ignition switch OFF. (2) Inspect the brake pads and linings for contam
ination with brake fluid, axle lubricant and/or an
BRAKE SYSTEM INSPECTION
other fluid.
BRAKE FLUID HOSES/TUBING
(3) Replace the brake pads and/or linings if they
are worn to within 0.78 mm (1/32 in) of the rivet
(1) Inspect all brake fluid rubber hoses (Fig. 9) for
head.
cracks, swelling, "kinks", a distorted condition and
fluid leakage. (4) Operate the rear brake self-adjuster lever and
(2) Inspect the brake fluid hoses and tubing that pivot. Test the operation of the self-adjuster screw for
are routed along the frame rail. ease of movement.
(5) Inspect the self-adjuster components for bent
PADS/LININGS, A D J U S T E R , W H E E L CYLINDERS AND
CALIPER areas, frayed cables, loose or overheated springs, and
The front disk brake pads can be visually inspected a binding condition.
via the brake caliper inspection ports.
(6) Inspect the disc brake caliper dust boot for cor TIRES
rect installation, damage/tears and indications of
brake fluid leakage. Inspect the bushings and pins RECOMMENDED MAINTENANCE
for corrosion, tears and a binding condition. The general condition of the tires and the inflation
(7) Pull the rear wheel cylinder dust boot back to pressures should be inspected at the same time the
expose the wheel cylinder housing and inspect for engine oil is changed and the oil filter is replaced.
fluid leaks. Inspect the pistons and cylinder bores for In addition, the tires/wheels should be rotated pe
proper appearance. riodically to ensure even tread wear and maximum
tread life. The tires/wheels should be rotated initially
(8) Inspect the brake differential warning valve
after the first 12 000-km (7,500-miles). Thereafter,
and housing for indications of leakage, "kinked"
hoses and loose fittings.
PARK BRAKE INSPECTION
(1) As applicable, engage the park brake lever or Inspect the tires for excessive wear, damage, etc.
pedal and then release it. Test the tires for the recommended inflation pres
(2) If the park brake is functioning normally, test sure. Refer to the tire inflation pressure decal located
it for smooth operation and vehicle-holding capabil on the inside of the glove box door, and also to Group
ity. 22-Tires And Wheels.
(3) Inspect the park brake cables for "kinks", fray
ing and a binding condition. ROTATION
(4) With the park brake released, the rear wheels Refer to Group 22—Tires And Wheels for the rec
should rotate without restriction. Adjust the park ommended method of tire/wheel rotation for a Jeep®
brake cable tension at the equalizer (Fig. 10), if nec vehicle.
essary.
BODY COMPONENTS
BRAKE
CABLE RECOMMENDED MAINTENANCE
Body components should be lubricated (as required)
LUBRICANT SPECIFICATIONS
All applicable exterior and interior body compo
nents should be:
• inspected for excessive wear,
• cleaned, and
• all pivot/sliding contact areas of the components
should be lubricated with the specified lubricant.
Refer to the Body Lubricant Specifications chart
below. When excessive wear is apparent, replace/re
pair as necessary.
Fig. 10 Park Brake Equalizer (XJ)—Typical LUBRICATION
(5) Repair any park brake malfunctions. All pivoting and sliding contact areas, including:
• seat tracks,
BRAKE OPERATIONAL T E S T • door hinges/latches/strikers, and
(1) Drive the vehicle and test for proper brake ac • liftgate/tailgate/hood hinges (Fig. 11),
tion. should be lubricated periodically to ensure quiet,
(2) Note any indication of drum/rotor overheating, easy operation and to protect against wear and cor
wheel dragging or the vehicle pulling to one side rosion.
when the brakes are applied. (1) As required, lubricate the body components
(3) Evaluate any performance complaints received with the specified lubricants.
from the owner/operator. (2) When lubricating door weatherstrip seals, ap
(4) Repair the brake system as necessary (refer to ply the lubricant to a cloth and wipe it on the seal.
Group 5—Brakes for additional information and ser (3) Prior to the application of lubricant, the compo
vice procedures). nent should be wiped clean to remove dust, grit and
debris. After lubrication, any excess lubricant should
be removed.
BODY LUBRICANT SPECIFICATIONS
COMPONENT SERVICE INTERVAL LUBRICANT

D o o r Hinges As Required Engine O i l
D o o r Latches As Required Multi-Purpose Grease N L G I G C - L B

(Water Resistant) (1)
H o o d Latch Release Mechanism & Safety Latch As Required Multi-Purpose Grease N L G I G C - L B 2 E P (2)
(When Performing
Other Underhood
Services)
Hood Hinges As Required Engine O i l
Seat Regulator & Track Release Mechanism As Required Multi-Purpose Grease N L G I G C - L B 2 E P (2)
Tailgate Hinge As Required Multi-Purpose Grease N L G I G C - L B 2 E P (2)
Tailgate Support Arms As Required Engine O i l
Tailgate Latches As Required W h i t e S p r a y Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease N L G I G C - L B 2 E P (2)
W i n d o w System Components (Regulators, Tracks, Rods As Required W h i t e S p r a y Lubricant (3)

& Channel Areas — Except Glass Run Weatherstrips
and Felt Lubricator, i f Equipped)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease N L G I G C - L B (1)
1. Mopar Wheel Bearing Grease (High Temperature)

2. Mopar Multi-Mileage Lubricant
3. Mopar S p r a y W h i t e Lube
4. Mopar Lock Cylinder Lubricant
J9200-58
(5) Extra close attention should also be given to

the hood latch components to ensure proper function
ing.
HEADLAMPS
Approximately every six months the headlamps
should be displayed on a vertical test surface. This
will ensure that the headlamps are positioned for
safe night-time driving.
BEAM AIM ADJUSTMENT

(1) Changes in the vehicle front and rear suspen
sion will alter the headlamp beam patterns and this
can cause unsafe night-time driving conditions.
Fig. 11 Hood Hinge Lubrication—XJ Vehicles (2) If a vehicle is loaded the headlamp beam pat
terns should be displayed on an vertical test surface
(4) Extra close attention should be given to exter and the headlamps "re-aimed".
nal key lock cylinders during the autumn and winter (3) Observe the headlamp beam patterns on an ap
months to ensure protection from water and ice. propriate vertical test surface and, if necessary, ad
just the headlamp beam "aim".
(4) If necessary, refer to Group 8L—Lamps for
headlamp "aim" adjustment procedures.
J F R O N T S U S P E N S I O N AND AXLE 2 - 1
FRONT SUSPENSION AND AXLE
CONTENTS
page page
A X L E N O I S E / V I B R A T I O N DIAGNOSIS
FRONT W H E E L ALIGNMENT
GENERAL INFORMATION
MODEL 3 0 AXLE AND T U B E A X L E (2WD)
16
5
1
. . 20
T O R Q U E SPECIFICATIONS
XJ F R O N T SUSPENSION
YJ FRONT SUSPENSION
48
10
13
I
GENERAL INFORMATION
FRONT SUSPENSION • Jounce bumpers (used to limit the travel of the
suspension)
XJ VEHICLES The front suspension is designed to allow each
The Cherokee front suspension is link/coil design wheel to adapt to different road surfaces without
comprised of (Fig. 1); greatly affecting the opposite wheel. The wheels are
• Drive axle (4WD), tube axle (2WD) mounted to hub/bearings that ride on tapered bear
• Track bar ings on the steering knuckle. The hub/bearing design
• Stabilizer bar is not serviceable and is replaced as a unit only. The
• Upper and lower suspension arms steering knuckles turn (pivot) on replaceable ball
• Coil springs studs mounted on the axle tube yokes.
• Dual-action shock absorbers
LINKS SHOCK UPPER STABILIZER COIL JOUNCE

ABSORBER SUSPENSION BAR SPRING BUMPER
LOWER
SUSPENSION TRACK
ARM BAR AXLE J9302-12
Fig. 1 XJ Front Suspension

2 -2 FRONT SUSPENSION AND AXLE J
The upper and lower suspension arms use bushings SHOCK UPPER
to isolate road noise. The suspension arms are bolted ABSORBER A N D SUSPENSION
LOWER ARM
to the frame and axle through the rubber bushings.
SUSPENSION BRACKET
The lower suspension arm uses cam bolts at the axle
to allow for caster and pinion angle adjustment. The
suspension arm travel (jounce or rebound) is limited
through the use of rubber bumpers.
All suspension components that use rubber bush COIL
SPRING
ings should be tightened with the vehicle at normal PAD
height. If the springs are not at their normal ride po
sition, vehicle ride comfort could be affected. Rubber
bushings must never be lubricated.
The vehicles use coil springs mounted up in the
fender shield that is part of the unitized body
bracket. There is a rubber doughnut isolator between
the top of the spring and bracket. The bottom of the TUBULAR
spring seats on the axle pad and is retained with a AXLE
clip.
Ride control is accomplished through the use of du STABILIZER
BAR
al-action shock absorbers. The shocks dampen the BRACKET
jounce and rebound as the vehicle travels over vari J9002-15
ous road conditions. The top of the shock absorbers
are bolted to the frame. The bottom of the shocks are Fig. 2 Front Axle— 2WD Vehicles
bolted to the axle spring bracket. SPACER BUSHING SHACKLE NUT
The stabilizer bar is used to minimize vehicle front
RETAINER
sway during turns. The spring steel bar helps to
GROMMET
equalize the vehicle body in relationship to the sus
BUSHING. RETAINER
pension. The bar extends across the front underside
of the chassis and connects to the frame rails. The SHOCK
SHACKLE ABSORBER
links are connected to the axle brackets. All mount
ing points of the stabilizer bar are isolated by rubber U-BOLTS
bushings.
The track bar is used to minimize front axle side-
to-side movement. The track bar is attached to the SHOCK
frame rail bracket with a ball stud and isolated with ABSORBER
a bushing at the axle bracket.
TUBE AXLE (2WD VEHICLES)

The front axle used on two-wheel drive vehicles is
a one-piece, tubular axle (Fig. 2). The tubular axle
mounts in the same bracketry as does the four-wheel )M BUSHING
drive front axle. The steering knuckles and hub bear
SPRING
ing assemblies are the same as used on the Model 30 BRACKET
drive axle.
J9217-4
YJ VEHICLES
The Wrangler (YJ) front suspension is leaf spring Fig. 3 YJ Front Suspension
design comprised of (Fig. 3); rail hangers through rubber bushings. The bushings
• Drive axle isolate road noise as the springs move. The forward
• Track bar end of the springs are attached to the frame by the
• Stabilizer bar use of shackles. Again the spring and shackles use
• Leaf springs rubber bushings to isolate road noise. The shackles
• Dual-action shock absorbers allow the springs to change their length as the vehi
• Jounce bumpers (used to limit the travel of the cle moves over various road conditions. The spring
suspension) and axle travel (jounce or rebound) is limited
The front suspension design uses semi-elliptic
through use of rubber bumpers mounted on the
multi-leaf springs and a solid drive axle. The rear
frame.
ward end of the springs are mounted to the frame
FRONT SUSPENSION AND AXLE 2-3
All suspension components that use rubber bush DIFFERENTIAL

ings should be tightened with the vehicle at the nor COVER
mal height. If the springs are not at their normal
ride position, vehicle ride comfort could be affected.
Rubber bushings must never be lubricated.
Ride control is accomplished through the use of du
al-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari
ous road conditions. The top of the shock absorbers
are bolted to the frame. The bottom of the shocks are
bolted to the axle bracket.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps the ve
hicle to maintain a flat attitude to the road surface.
The bar extends across the front underside of the
chassis and connects to the frame rails. The links are
connected to the axle brackets. All mounting points
of the stabilizer bar are isolated by rubber bushings. FILL P L U G
The track bar is used to minimize front axle side-

IDENTIFICATION
to-side movement. The track bar is attached to the TAG J9202-22
frame rail bracket with a ball stud and isolated with
a bushing at the axle bracket. Fig. 4 Model 30 Differential Cover
F O U R W H E E L DRIVE DISCONNECT VACUUM
FRONT DRIVE AXLE SHIFT
INDICATOR L A M P S W I T C H HOUSING«
It is not necessary to remove the complete axle MOTOR
from the vehicle for routine or differential service. If INTERMEDIATE
the differential housing or axle shaft tubes are dam RIGHT AXLE
AXLE SHAFT
S H A F T SEAL
aged, the complete axle can be removed and in
stalled.
For complete drive axle assembly removal and in
stallation refer to Drive Axle Assembly Replacement
in this Group.
The removable cover provides for servicing without BUSHING S H I F T FORK S H I F T COLLAR J9202-57
removing axle from vehicle.
The integral type housing, hypoid gear design has Fig. 5 Disconnect Feature
the centerline of the pinion set above the centerline
pinion gear is fitted in a bore in the differential case
of the ring gear.
and is positioned at a right angle to the axle shafts.
The Model 30 axle has the assembly part number
In operation, power flow occurs as follows:
and gear ratio listed on a tag. The tag is attached to
the housing cover (Fig. 4). Build date identification • Pinion gear rotates the ring gear
codes are stamped on the axle shaft tube cover side. • Ring gear (bolted to the differential case) rotates
XJ axles are equipped with an optional A.B.S. the case
brake system. The A.B.S. tone rings are pressed onto • Differential pinion gears (mounted on the pinion
the axle shaft near the hub and knuckle. For addi mate shaft in the case) rotate the side gears
tional information on the A.B.S. system refer to • Side gears (splined to the axle shafts) rotate the
Group 5, Brakes. shafts
• XJ vehicles use the non-disconnect feature. During straight-ahead driving, the differential pin
• YJ vehicles use the vacuum axle disconnect fea ion gears do not rotate on the pinion mate shaft. This
ture (Fig. 5). occurs because input torque applied to the gears is
divided and distributed equally between the two side
STANDARD DIFFERENTIAL OPERATION gears. As a result, the pinion gears revolve with the
The differential gear system divides the torque be pinion mate shaft but do not rotate around it (Fig. 6).
tween the axle shafts. It allows the axle shafts to ro When turning corners, the outside wheel must
tate at different speeds when turning corners. travel a greater distance than the inside wheel in or
Each differential side gear is splined to an axle der to complete a turn. This difference must be com
shaft. The pinion gears are mounted on a pinion pensated for in order to prevent the wheels from
mate shaft and are free to rotate on the shaft. The scuffing and skidding through the turn. To accom-
2 -4 FRONT SUSPENSION AND AXLE J
IN STRAIGHT A H E A D DRIVING
AXLE <fe
EACH W H E E L ROTATES A T 100%
O F CASE S P E E D
OUTER WHEEL 100% D I F F E R E N T I A L INNER WHEEL
/
110% CASE S P E E D CASE S P E E D 9 0 % CASE S P E E D
P I N I O N G E A R S ROTATE P I N I O N G E A R S ROTATE
W I T H CASE J9303-13 O N PINION SHAFT J9303-14
Fig. 6 Differential Operation—Straight-Ahead Fig. 7 Differential Operation—On Turns

Driving
plish this, the differential becomes effective allowing
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. The pinion gears now
rotate around the pinion mate shaft in opposite direc
tions. This allows the side gear and axle shaft at
tached to the outside wheel to rotate at a faster
speed.
J FRONT SUSPENSION AND AXLE 2 -S
FRONT WHEEL ALIGNMENT

GENERAL INFORMATION wheel off-center. The wheel toe position is the final
Front wheel alignment involves the correct posi front wheel alignment adjustment.
tioning of the tire contact patch in relation to the • STEERING AXIS INCLINATION ANGLE is mea
pavement, The positioning is accomplished through sured in degrees and is the angle that the steering
the suspension and steering linkage adjustments. An knuckles are tilted (Fig. 1). The inclination angle has
alignment is essential for efficient steering and direc a fixed relationship with the camber angle. This will
tional stability. The most important factors of front not change except when a spindle or ball stud is
end alignment are camber, caster and toe position. damaged or bent. The angle is not adjustable and the
Routine inspection of the front suspension and damaged component(s) must be replaced to correct
steering components is a good preventative mis-alignment.
maintenance practice. Inspection also helps to
ensure safe operation of the vehicle. CAUTION: Do not attempt to modify any suspension
• CAMBER is the number of degrees the top of the or steering component by heating and bending.
wheel is tilted either inward or outward. An excessive
negative camber angle will cause tread wear at the in
PRE-ALIGNMENT INSPECTION
side of the tire. An excessive positive camber angle will
Before starting a front wheel alignment, the following
cause tread wear at the outside of the tire (Fig. 1).
inspection and necessary corrections must be completed.
• CASTER is the number of degrees of forward or
(1) Tires with the same recommended air pressure,
rearward tilt of the steering knuckles. Forward tilt
size, and tread wear. Refer to Group 22, Wheels and
provides a negative caster angle. Rearward tilt pro Tires for diagnosis information.
vides a positive caster angle (Fig. 1). (2) Front wheel bearings for wear or adjustment.
• WHEEL TOE POSITION is the difference between (3) Ball studs and linkage pivot points, steering
the leading and trailing inside edges of the front gear for looseness, roughness, binding or a sticking
tires (Fig. 1). Incorrect wheel toe position is the most condition. Refer to Group 19, Steering for additional
common cause of unstable steering and steering information.
CASTER CAMBER TOE
POSITIVE CASTER
PIVOT FRONT OF VEHICLE

CENTERLINE NEGATIVE TOE (TOE OUT) B>A
POSITIVE TOE (TOE IN) 6<A
SCRUB
STEERING WHEEL CENTER RADIUS
NEGATIVE CAMBER (SHOWN) THRUST ANGLE
TOP Of WHEEL INBOARD
POSITIVE CAMBER (NOT SHOWN)
TOP OF WHEEL OUTBOARD
0.5 CCW
NOMINAL-PREFERRED
THE NOMINAL VALUE IS
THE PREFERRED VALUE
LEFT/RIGHT DIFFERENCE
ANGLE OF REAR AXLE RELATIVE TO VEMQE CENTER1JNE
THE VALUE OF THE LEFT SDE
0.5 CW MINUS THE VALUE OF THE W AXLE POINTS LEFT (-) AXLE POINTS RIGHT
RIGHT SIDE
EX.
LEFT CASTER-+6.5
RIGHT CASTER * +8.0
PRODUCTION TOLERANCE
THE RANGE Of ACCEPTABLE PRODUCTION: +6.5/+7.S
VALUES AROUND THE NOMINAL PREFERRED; +7.0
CCW - COUNTER CLOCKWISE LEFT/RIGHT DIFFERENCE
CW - CLOCKWISE 6.5-8.0- 1.5 TOLERANCE: 0.5
J9302-61
Fig. 1 Wheel Alignment Measurements

2-6 FRONT SUSPENSION AND AXLE
SUSPENSION AND STEERING SYSTEM DIAGNOSIS

J
L O O S E OR W O R N LOOSE OR W O R N LOW OR U N E V E N LOW OR U N E V E N LOW OR U N E V E N

LOOSE OR W O R N
FRONT W H E E L FRONT W H E E L T I R E AIR P R E S S U R E T I R E AIR P R E S S U R E TIRE P R E S S U R E
W H E E L BEARINGS
BEARINGS BEARINGS
LOOSE OR W O R N
SHOCK A B S O R B E R LOOSE O R W O R N LOOSE, W O R N OR WHILE BRAKING-
TIRE/WHEEL LOOSE GLAZED PIS REFER TO
M O U N T I N G HARD S T E E R I N G COLUMN
O U T O F BALANCE W H E E L BEARINGS PUMP BELT BRAKES SERVICE
WARE OR S H A F T COUPLING
SHOCK A B S O R B E R
U N E V E N TIRE T R E A D
LOOSE S T E E R I N G LOOSE SJ E E R I N G LC)W
W E A R , OR EX B R O K E N <DR W E A K BROKEN OR W E A K
GEAR-TC }-FRAME GEAR-TC D-FRAME P O W E R 5J E E R I N G
CESSIVELY W O R N R E A R S PRING REAR S P R I N G
RAIL BOLTS RAIL BOLTS FLUID LEVEL
TIRE TREAD
WC)RN W O R IN T I E - WORN TIE- SHOCK A BSORBER :

LACK Ol A S S I S T LOOSE O R W O R N
U P P E R S U !S P E N S I O N ROD E N D ROD E N D NOT FUNCZTIONING F R O M I >OWER SUSPENSION
ARM BU S H I N G S BALLS •TUDS BALL S T U D S CORR ECTLY STEERIN G P U M P BUSHINGS
INCORRECT F R O N T
W O R N LOWER INCORRECT LOOSE O R W O R N INCORRECT BALL S T U D S WHEEL ALIGNMENT
S U S P E N S •ION ARM S T E E R I N G GEAR S U S P E N S I O N ARM S T E E R I N G GEAR REQUIRE (EITHER CASTER
PIVOT B lJ S H I N G S ADJUSTMENT BUSHINGS ADJUSTMENT LUBRICATION OR CAMBER)
LOOSE O R W O R N LOOSE O R W O R N S T E E R I N G GEAR

LOOSE LOWER
S U S P E N S I O N ARM UPPER S U S P E N S I O N S U S P E N S I O N ARM LUBRICANT LEVEL
ARM BALL S T U D S BUSHINGS LOW
W O R N ISOLATOR INCORRECT FRONT-

INCORRECT F R O N T INCORRECT
PAD B E T W E E N COIL W H E E L ALIGNMENT
S T E E R I N G GEAR
SPRING AND (PARTICULARLY W H E E L ALIGNMENT
ADJUSTMENT
FRAME BRACKET CASTER)
STEERING
GEAR
MALFUNCTION
INCORRECT F R O N T
W H E E L ALIGNMENT
(PARTICULARLY
CASTER)
J9002-97
J . , FRONT SUSPENSION AND AXLE 2 - 7
(4) Front wheels for excessive radial, lateral

runout and unbalance. Refer to Group 22, Wheels
and Tires for diagnosis information.
(5) Suspension components for wear and noise.
Check components for correct torque. Refer to Groups
2 and 3, Suspension and Axle for additional informa
tion.
A L I G N M E N T M E A S U R E M E N T S AND A D J U S T M E N T S
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each bumper
at the center and jounce the vehicle up and down
several times. Always release the bumper when it's
at the down position. Set the front end alignment
to specifications while the vehicle is in its NOR
M A L L Y LOADED CONDITION. Fig. 2 Adjustment— YJ Vehicles
CAMBER
The wheel camber angle (Fig. 1) is preset at ZERO
DEGREES (0°). The angle is not adjustable and can
not be altered.
CASTER
The caster angle (Fig. 1) is set at:
• XJ manual transmission, POSITIVE 6.5 DE
GREES ( + 6.5°).
• XJ automatic transmission, POSITIVE 8.0 DE
GREES ( + 8.0°).
• YJ all transmissions, POSITIVE 6.0 DEGREES
( + 6.0°).
Check the caster of the front axle for correct angle.
Be sure the axle is not bent or twisted. Road test the
vehicle and observe the steering wheel return-to-cen
ter position.
During the road test, turn the vehicle to both the
left and right. If the steering wheel returns to the J8916-22
center position unassisted, the caster angle is correct.
However, if steering wheel does not return toward Fig. 3 Adjustment—XJ Vehicles
the center position unassisted, an incorrect caster an
specifications. Position the clamp bolts as shown
gle is probable.
(Fig. 5) and tighten to 49 N*m (36 ft. lbs.) torque.
Caster can be adjusted by installing the appropri
Make sure the toe setting does not change dur
ate size shims (Fig. 2, 3). Changing caster angle
ing clamp tightening.
will also change the front propeller shaft angle.
The propeller shaft angle has priority over (4) Adjust the left wheel toe position with the tie
caster. Refer to Group 16, Propeller Shafts for rod. Turn the sleeve until the left wheel is at speci
additional information. fications. Position the clamp bolts as shown (Fig. 5)
and tighten to 27 N»m (20 ft. lbs.) torque. Make sure
TOE POSITION-XJ VEHICLES the toe setting does not change during clamp
The wheel toe position adjustment should be the fi tightening.
nal adjustment. (5) Verify the right toe setting.
(1) Start the engine and turn wheels both ways be
fore straightening the wheels. Secure the steering TOE POSITION— YJ VEHICLES
wheel with the front wheels in the straight-ahead po The wheel toe position adjustment should be the fi
sition. nal front wheel alignment adjustment. In all in
(2) Loosen the adjustment sleeve clamp bolts (Fig. stances, follow the equipment manufacturer's
4). recommended procedure.
(3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
2 - 8 FRONT SUSPENSION AND AXLE
J
NUT PITMAN NUT
ARM
COTTER PIN
LUBE FITTING
CLAMP
ADJUSTMENT
DRAG CLAMPS
LINK
STEERING DAMPENER J9202-1
Fig. 4 Steering Linkage—XJ Vehicles

TIE ROD
(1) Secure the steering wheel with the front wheels
CLAMP in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight
ening the wheels.
With power steering, the engine should be op
erating during the wheel toe position adjust
ment.
(2) Loosen the adjustment sleeve clamp bolts on
the tie rod (Fig. 6).
The tie rod and adjustment sleeve have both
right and left hand threads to provide equal ad
justment for eaeh wheel.
(3) After the adjustment is completed, position the
DRAG LINK
tie rod adjustment sleeve clamp bolts as shown.
CLAMPS J9302-10 (4) Tighten the adjustment sleeve clamp bolts to
Fig. 5 Drag Link and Tie Rod Clamp Location (5) The steering wheel can be centered by the drag
link. Complete the adjustment. Position the drag link
clamp bolts as shown. Tighten the bolts to 49 N*m
J FRONT SUSPENSION A N D A X L E 2 - 9
NUT BOLT
PITMAN
ARM
NUT
TIE ROD
END
CLAMP
COTTER
DRAG PIN ' T I E ROD
LINK CLAMP END TIE ROD END J9202-2
Fig. 6 Steering Linkage

YJ Vehicles
ALIGNMENT SPECIFICATIONS-XJ VEHICLES ALIGNMENT SPECIFICATIONS-YJ VEHICLES
Adjustment Set-To O K Range Adjustment Set-To O K Range
TOE:
TOE: Right Wheel 0° 1/16 inch IN
1/16 inch OUT
Right Wheel 0° 1/32 inch IN
to 1/32 inch O U T Left Wheel 0° 1/16 inch IN
1/16 inch OUT
Left Wheel 0° 1/32 inch IN
to 1/32 inch O U T CAMBER 0° -1/2° to +1/2°
CASTER:
Manual Trans. 6.5° 5-1/4° to 7-1/4°
CAMBER 0° + 1/2° to - 3 / 4 °
Auto. Trans. 8.0° 6-1/2° to 9°
OUTSIDE WHEEL
T U R N ANGLE* 33° 32° to 33°
CASTER 6° 5° to 9°
Steering stops are not adjustable. J9102-15
OUTSIDE W H E E L 33° MAX. 33° to 32°

TURN ANGLE*
J9002-23
•STEERING STOPS ARE N O T ADJUSTABLE.
2 - 10 FRONT SUSPENSION AND AXLE J
XJ FRONT SUSPENSION
INDEX
page page
Axle Bushing Replacement 11 Spring and Shock Diagnosis 12
Coil Spring 13 Stabilizer Bar 10
Lower Suspension Arm . 12 Track Bar 10
Service Information 10 Upper Suspension Arm 11
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE INFORMATION (4) Remove the frame rail bracket nuts and bolts
to remove the track bar bracket (Fig. 1).
CAUTION: All suspension components that use rub
ber bushings should be tightened with the vehicle INSTALLATION
at the normal height, it is important to have the (1) Install the frame rail bracket and install the
springs supporting the weight of the vehicle when bolts and nuts (Fig. 1).
the fasteners are torqued. If the springs are not at (2) Tighten the bracket to reinforcement plate bot
their normal ride position, vehicle ride comfort tom bolts to 121 N«m (90 ft. lbs.) torque. Tighten the
could be affected along with premature rubber bracket to stud plate nuts to 100 N»m (74 ft. lbs.)
bushing wear. Rubber bushings must never be lu torque. Tighten the reinforcement plate side nuts to
bricated. 121 N«m (90 ft. lbs.) torque.
(3) Install the track bar at axle tube bracket.
Loosely install the retaining bolt and flag nut (Fig.
TRACK BAR 1).
REMOVAL (4) It may be necessary to pry the axle assembly
(1) Raise and support the vehicle. over to install the track bar at the frame rail. Install
(2) Remove the cotter pin and nut from the ball track bar at the frame rail bracket (Fig. 1). Install
stud end at the frame rail bracket (Fig. 1). the retaining nut on the stud.
A puller tool may be necessary to separate the (5) Remove the supports and lower the vehicle.
ball stud from the frame rail bracket. (6) Tighten the retaining bolt at the axle shaft
(3) Remove the bolt and flag nut from the axle tube bracket to 100 N»m (74 ft. lbs.) torque.
shaft tube bracket (Fig. 1). Remove the track bar. (7) Tighten the ball stud nut to 85 N«m (63 ft. lbs.)
torque. Install a new cotter pin.
NUT
STABILIZER BAR
REMOVAL
(2) Disconnect the stabilizer bar links from the
axle brackets (Fig. 2).
(3) Disconnect the stabilizer bar from the links.
(4) Disconnect the stabilizer bar clamps from the
frame rails. Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 75 N«m (40 ft. lbs.).
(2) Install the links and grommets onto the stabi
lizer bar and axle brackets (Fig. 2). Tighten the nut
at the connecting links at the axle bracket to 95 N»m
(3) Tighten the stabilizer bar to connecting link
nut to 36 N-m (27 ft. lbs.) torque.
Fig. 1 Track Bar (4) Remove the supports and lower the vehicle.
J FRONT SUSPENSION AND AXLE 2 - 11
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail (Fig. 3).
(2) Install the bolts and finger tighten the nuts
(Fig. 3).
(3) Remove the supports and lower the vehicle.
(4) Tighten the nut at the axle to 75 N-m (55 ft.
lbs.) torque.
Tighten the nut at the frame bracket to 90 N-m (66
ft. lbs.) torque.
AXLE BUSHING R E P L A C E M E N T
(1) Remove the upper suspension arm from axle.
Refer to Upper Suspension Arm Removal in this
Group.
(2) Insert Spacer 7932-3 (J-35581-3) around the
bushing in the axle bracket ears (Fig. 4).
(3) Assemble and install Bushing Remover/In
staller (Fig. 4).
(4) Remove the bushing by tightening the hex-
head on Long Nut.
Fig. 2 Stabilizer Bar
UPPER SUSPENSION A R M
REMOVAL
(2) Remove the upper suspension arm nut and bolt
at the axle bracket (Fig. 3).
(3) Remove the nut and bolt (Fig. 3) at the frame
rail and remove the upper suspension arm.
NUT
J9302-9
Fig. 4 Axle Bracket Bushing Removal

For two-wheel drive axles and right side on
Model 30 axle, do not remove Spacer 7932-3 (J-
35581-3) at this time.
(5) Position the new bushing on Installer.
(6) Install the bushing by tightening the hex-head
on Long Nut (Fig. 5). Remove Spacer 7932-3 (J-
ARM
35581-3).
J9202-7
(7) Install the upper suspension arm to axle. Refer
Fig. 3 Upper and Lower Suspension Arms to Upper Suspension Arm Installation in this Group.
AXLE SPECIAL 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) Lower the vehicle.
(4) Tighten the front and rear nuts to 115 N»m (85
ft. lbs.) torque.
S P R I N G AND S H O C K DIAGNOSIS
A squeak noise from the shock absorber can be pro
duced if movement between the rubber bushings and
the metal occurs. This noise can usually be stopped
by tightening the attaching nuts. If the squeak noise
persists, inspect for damaged and worn bushings, and
attaching components. Repair as necessary if any of
these conditions exist.
The shock absorber bushings do not require any
type of lubrication. Do not lubricate the bushings to
J9302-8 reduce bushing noise. Grease or mineral oil-base lu
bricants will deteriorate the bushing.
Fig. 5 Axle Bracket Bushing installation The shock absorbers are not refillable or adjust
LOWER SUSPENSION ARM able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
REMOVAL an upright position and force the piston into and out
(1) Raise and support the vehicle. of the cylinder four or five times. The action through
(2) Remove the lower suspension arm nut and bolt out each stroke should be smooth and even.
from the axle bracket (Fig. 3).
(3) Remove the nut and bolt (Fig. 3) from the rear SHOCK ABSORBER
bracket and remove the lower suspension arm.
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment (Fig. 6).
Fig. 6 Coil Spring & Shock Absorber

J F R O N T S U S P E N S I O N AND AXLE 2 -13
(2) Remove the lower nuts and bolts from the axle (6) Disconnect the track bar from the frame rail
bracket (Fig. 6). Remove the shock absorber. bracket.
(7) Disconnect the drag link from the pitman arm.
INSTALLATION (8) Lower the axle until the spring is free from the
(1) Position the lower retainer and grommet on the upper mount. Remove the coil spring clip screw (Fig.
upper stud. Insert the shock absorber through the 6) and remove the spring.
shock tower hole. (9) Remove the jounce bumper if necessary from
(2) Install the lower bolts and nuts. Tighten nuts the upper spring mount (Fig. 6).
to 19 N-m (14 ft. lbs.) torque.
(3) Install the upper grommet and retainer on the INSTALLATION
stud in the engine compartment. Install the nut and (1) Install the jounce bumper on the upper spring
tighten to 23 N-m (17 ft. lbs.) torque. mount. Tighten the screw to 42 N-m (31 ft. lbs.)
torque (Fig. 6).
COIL SPRING
(2) Position the coil spring on the axle pad. Install
REMOVAL the spring clip and screw (Fig. 6). Tighten the screw
(1) Raise and support the vehicle. Position a hy to 21 N-m (16 ft. lbs.) torque.
draulic jack under the axle to support it. (3) Raise the axle into position until the spring
(2) Remove the wheel if necessary. seats in the upper mount.
(3) Mark and disconnect the front propeller shaft (4) Connect the stabilizer bar links and shock ab
from the axle. sorbers to the axle bracket. Connect the track bar to
(4) Disconnect the lower suspension arm from the the frame rail bracket.
axle (Fig. 6). (5) Install the lower suspension arm to the axle.
(5) Disconnect the stabilizer bar link and shock ab (6) Install the front propeller shaft to the axle.
sorber from the axle. (7) Remove the supports and lower the vehicle.
YJ FRONT SUSPENSION
INDEX
page page
Leaf Spring . 15 Spring and Shock Diagnosis 14
Leaf Spring Eye Bushing Replacement 15 Stabilizer Bar 14
Service Information . 13 Track Bar 13
Shock Absorber 14
SERVICE INFORMATION FRAME LEFT

It is important to have the springs supporting MOUNT FRAME R A I L
the weight of the vehicle when the track bar fas
teners are being torqued. If the springs are not
at their normal ride position, vehicle ride com
fort could be affected along with premature rub
ber bushing wear.
TRACK BAR
REMOVAL
NUT
(2) Remove the retaining nuts and bolts (Fig. 1)
from the axle bracket and frame bracket. TRACK
BAR
INSTALLATION 'FRONT
(1) Position track bar at axle shaft tube bracket. AXLE V I E W I N DIRECTION
Loosely install the retaining bolt and nut (Fig. 1). OF A R R O W Y
(2) Install the retaining bolts and nuts.
(3) Tighten the retaining nut at the axle shaft
tube bracket to 100 N-m (74 ft. lbs.) torque. TRACK BOLT
BAR J9202-4
Fig. 1 Track Bar

(4) Tighten the retaining nut at the frame bracket reduce bushing noise. Grease or mineral oil-base lu
to 168 N-m (125 ft. lbs.) torque. bricants will deteriorate the bushing.
The shock absorbers are not refillable or adjust
STABILIZER BAR able. If a malfunction occurs, the shock absorber
REMOVAL
an upright position and force the piston into and out
of the cylinder four or five times. The action through
(2) Remove the retaining nut from the connecting
link bolt (Fig. 2). out each stroke should be smooth and even.
SWAY SHOCK ABSORBER

'BAR COTTER
PIN REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud on the frame bracket (Fig. 3).
(3) Remove the nut, washers and bolt from the
shock absorber lower eye (Fig. 3).
SPACER BUSHING SHACKLE NUT
RETAINER
GROMMET
BUSHING RETAINER
BOLT
SHOCK
ABSORBER
RETAINER J9202-6
Fig. 2 Stabilizer Bar

(3) Remove the bracket retaining nuts and brack FRONT
ets. AXLE
(4) Remove the stabilizer bar.

BUSHING
SPRING SPRING
INSTALLATION
BRACKET
(1) Inspect the stabilizer bar bushings (Fig. 2). Re
place the bushings if cracked, cut, distorted, or worn.
/^0ÎEW
^ *
IN DIRECTION
OF A R R O W X J9217-4
(2) Position the stabilizer bar on the frame. Install

the retaining brackets and fasteners. Tighten bolts to Fig. 3 Spring & Shock Absorber
41 N-m (30 ft. lbs.) torque. (4) Remove the shock absorber.
(3) Install the link upper bolts and nuts. Tighten (5) Remove the remaining grommet and retainer
the nuts to 61 N-m (45 ft. lbs.) torque. from the shock absorber stud.
(4) Tighten the link spring bracket nuts to 61 N-m
(45 ft. lbs.) torque. INSTALLATION
(5) Lower the vehicle. (1) Position the lower retainer and grommet on the
upper stud. Insert the shock absorber through the
S P R I N G AND S H O C K DIAGNOSIS
shock tower hole.
A squeak noise from the shock absorber or springs
(2) Install the lower bolts and nuts. Tighten the
can be produced if movement between the rubber
nuts to 61 N-m (45 ft. lbs.) torque.
bushings and the metal occurs. This noise can usu
(3) Install the upper grommet and retainer on the
ally be stopped by tightening the attaching nuts. If
stud on the frame bracket. Install the nut and
the squeak noise persists, inspect for dainaged and
worn bushings, and attaching components. Repair as tighten to 23 N-m (17 ft. lbs.) torque.
necessary if any of these conditions exist.
The shock absorber bushings do not require any
type of lubrication. Do not lubricate the bushings to
J FRONT SUSPENSION AND AXLE 2 15
LEAF SPRING LEAF SPRING EYE BUSHING REPLACEMENT

(1) Assemble tools shown (Fig. 4). Tighten the nut
REMOVAL located at the socket wrench end of the threaded rod
(1) Raise the vehicle.
until the bushing is forced out.
(2) Support the vehicle with jack stands placed un
der the frame. NUT PIPE
(RECEIVER)
(3) Position a hydraulic jack under the axle. Raise
the axle to relieve the axle weight from the springs.
(4) Loosen, but do not remove the stabilizer bar SPRING
link attaching nut (Fig. 3). EYE
(5) Remove the nuts, the U-bolts and spring
bracket from the axle.
(6) Remove the nut and bolt that attaches the
spring front eye to the shackle.
(7) Remove the nut and bolt from the spring rear
NUT
eye.
(8) Remove the spring from the vehicle.
The spring can be disassembled by removing
the spring clips and the center bolt. If the spring
bushings require replacement, refer to the bush
ing removal and installation procedures.
SOCKET
WRENCH
INSTALLATION (DRIVER)
(1) Position the spring front eye in the shackle.
Loosely install the attaching bolt and nut. Do not
FLAT THREADED
tighten at this time. WASHER ROD J8917-20
(2) Position the rear eye in the hanger bracket.
Loosely install the attaching bolt and nut (Fig. 3). Do Fig. 4 Spring Eye Bushing Removal
not tighten at this time.
(3) Position the axle. Install the spring bracket, (2) Assemble and align the bushing installation
U-bolts and nuts (Fig. 5). Tighten the U-bolt nuts to tools.
122 N-m (90 ft. lbs.) torque. (3) Align the bushing with the spring eye and
(4) Attach the stabilizer bar. tighten the nut located at the socket wrench end of
(5) Remove the hydraulic jack. the threaded rod. Tighten until the bushing is forced
(6) Remove the support stands and lower the vehi into the spring eye.
cle. The bushing must be centered in the spring
(7) Tighten the front shackle plate nut (Fig. 3) to eye. The ends of the bushing must be flush or
129 N-m (95 ft. lbs.) torque. slightly recessed within the end surfaces of the
(8) Tighten the rear eye bracket nut to 142 N-m spring eye.
2 - 1 6 F R O N T S U S P E N S I O N AND A X L E
J
AXLE NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Oriveline Snap 17 Low Speed Knock 17
Gear and Bearing Noise 16 Vibration 17
General Information 16
GENERAL INFORMATION GEAR AND BEARING NOISE

Axle bearing problem conditions are usually caused
by: GEAR NOISE
• Insufficient or incorrect lubricant Axle gear noise can be caused by insufficient lubri
• Foreign matter/water contamination cant. Incorrect backlash, tooth contact, or worn/dam
• Incorrect bearing preload torque adjustment aged gears can cause noise.
When serviced, the bearings must be cleaned thor Gear noise usually happens at a specific speed
oughly. They should be dried with lint-free shop tow range. The range is 30 to 40 mph, or above 50 mph.
els. Never dry bearings with compressed air. The noise can also occur during a specific type of
This will overheat them and brinell the bearing driving condition. These conditions are acceleration,
surfaces. This will result in noisy operation after deceleration, coast, or constant load.
repair. When road testing, accelerate the vehicle to the
Axle gear problem conditions are usually the result speed range where the noise is the greatest. Shift
of: out-of-gear and coast through the peak-noise range.
• Insufficient lubrication If the noise stops or changes greatly, check for insuf
• Incorrect or contaminated lubricant ficient lubricant. Incorrect ring gear backlash, or
• Overloading (excessive engine torque) gear damage can cause noise changes.
• Incorrect clearance or backlash adjustment Differential side and pinion gears can be checked
Insufficient lubrication is usually the result of a by turning the vehicle. They usually do not cause
housing cover leak. It can also be from worn axle noise in straight-ahead driving. These gears are
shaft or pinion gear seals. Check for cracks or porous loaded during vehicle turns. If noise does occur dur
areas in the housing or tubes. ing vehicle turns, the side or pinion gears could be
Using the wrong lubricant will cause overheating worn or damaged. A worn pinion gear mate shaft can
and gear failure. Gear tooth cracking and bearing also cause a snapping or a knocking noise.
spalling are indicators of this.
Axle component breakage is most often the result BEARING NOISE
The axle shaft, differential and pinion gear bear
of:
ings can all produce noise when worn or damaged.
• Severe overloading
Bearing noise can be either a whining, or a growling
• Insufficient lubricant
sound.
• Incorrect lubricant Pinion gear bearings have a constant-pitch noise.
• Improperly tightened components This noise changes only with vehicle speed. Pinion
Common causes of overloading is from full-throttle bearing noise will be higher because it rotates at a
acceleration. Component breakage can occur when faster rate. Drive the vehicle and load the differen
the wheels are spun excessively. Insufficient or incor tial. If bearing noise occurs the pinion rear bearing is
rect lubricants contribute to breakage through over the source of the noise. If the bearing noise is heard
heating. Loose differential components can also cause during a coast, front bearing is the source.
breakage. Worn, damaged differential bearings usually pro
Incorrect bearing preload or gear backlash will not duce a low pitch noise. Differential bearing noise is
result in component breakage. Mis-adjustment will similar to pinion bearing. The pitch of differential
produce enough noise to cause service repair before a bearing noise is also constant and varies only with
failure occurs. If a mis-adjustment condition is not vehicle speed.
corrected, component failure can result. Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise can contribute to what appears to be a rear-end vi
is usually not noticeable at speeds above 30 mph. bration. Do not overlook engine accessories, brackets
and drive belts.
L O W S P E E D KNOCK All driveline components should be examined be
Low speed knock is generally caused by a worn fore starting any repair.
U-joint or by worn side-gear thrust washers. A worn Refer to Group 22, Wheels And Tires for additional
pinion gear shaft bore will also cause low speed information.
knock.
DRIVELINE SNAP
VIBRATION
A snap or clunk noise when the vehicle is shifted
Vibration at the rear of the vehicle is usually
caused by a: into gear (or the clutch engaged), can be caused by:
• Damaged drive shaft • High engine idle speed
• Missing drive shaft balance weight • Loose engine/transmission/transfer case mounts
• Worn, out-of-balance wheels • Worn U-joints
• Loose wheel lug nuts • Loose spring mounts
• Worn U-joint • Loose pinion gear nut and yoke
• Loose spring U-bolts • Excessive ring gear backlash
• Loose/broken springs • Excessive differential side gear-to-case clearance
• Damaged axle shaft bearings The source of a snap or a clunk noise can be deter
• Loose pinion gear nut mined with the assistance of a helper. Raise the ve
• Excessive pinion yoke run out hicle on a hoist with the wheels free to rotate.
• Bent axle shaft Instruct the helper to shift the transmission into
Check for loose or damaged front-end components gear. Listen for the noise, a mechanics stethoscope is
or engine/transmission mounts. These components helpful in isolating the source of a noise.
2-18 FRONT SUSPENSION AND AXLE
SERVICE DIAGNOSIS
Condition Possible Cause Correction

W H E E L NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
AXLE S H A F T NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearings. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct as
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(f) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
D I F F E R E N T I A L CASE (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
D I F F E R E N T I A L GEARS (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
L O S S OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
FRONT SUSPENSION AND AXLE 2 - 19
SERVICE DIAGNOSIS {CONT'Df

(b) Worn axle shaft seals. (b) Replace worn seals.
(c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal.
(e) Scored and worn yoke. (f) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
A X L E OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash. (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR T E E T H B R O K E (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
A X L E NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
MODEL 30 AXLE AND TUBE AXLE (2WD)
INDEX
page page
Axle Bushing Replacement 33 Drive Axle Assembly Replacement—YJ Vehicles . 21
Axle Shaft—Cardan U-Joint 24 Final Assembly 45
Axle Specifications 47 General Information 20
Backlash and Contact Pattern Analysis . 45 Hub Bearing and Axle Shaft 24
Cleaning/Inspection 35 Inner Axle Shaft Oil Seal Replacement . 34
Differential and Pinion Measurement with Gauge Lubricant Change ........................ 22
Set D-115-30 ............... . . . . . . . 39
Differential Assembly 37 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . 20
Differential Disassembly 34 Pinion Gear Assembly/Installation 41
Differential Installation 44 Pinion Gear Depth Information 38
Differential Removal 33 Pinion Removal/Disassembly . 34
Differential Shim Pack Measurement and Pinion Shaft Seal Replacement . 23
Adjustment 43 Steering Knuckle and Ball Studs 31
Drive Axle Assembly Replacement—XJ Vehicles . 21 Vacuum Disconnect Axle—YJ Vehicles 25
GENERAL INFORMATION • Original pinion depth shim pack is lost or mis

The Model 30 front axle consists of an iron center placed
casting with axle shaft tubes extending from either • Replacing the differential case
side. The tubes are pressed into and welded to the • Original differential bearing shim pack is lost or
housing to form a one-piece axle. misplaced
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline COMMAND-TRAC— YJ VEHICLES
of the ring gear. The Command-Trac system is a vacuum disconnect
The axle has a fitting for a vent hose used to re axle. The system has a two-piece axle shaft coupled
lieve internal pressure caused by lubricant vaporiza together by a shift collar. The intermediate axle
tion and internal expansion. shaft in retained with a C-clip in the side gear of the
The axles are equipped with semi-floating axle differential. For two-wheel drive operation, the vac
shafts, meaning that loads are supported by the hub uum motor and shift fork disengages the axle shaft
bearings. The axle shafts are retained by nuts at the splines. For four-wheel drive operation, the vacuum
hub bearings. The hub bearings are bolted to the motor and shift fork engages the splines.
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly. SELEG-TRAC-XJ VEHICLES
The axles are equipped with ABS brake sensors. The Selec-Trac system is a non-disconnect axle.
The sensors are attached to the knuckle assemblies Shifting from two-wheel to four-wheel drive is at the
and tone rings are pressed on the axle shaft. Use transfer case.
care when removing axle shafts as NOT to dam For XJ vehicles equipped with Selec-Trac and
age the tone wheel or the sensor. ABS brake system, refer to Group 5, Brakes for ad
The cover provides a means for servicing the differ ditional service information.
ential without removing the axle assembly.
The Model 30 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
Multi-purpose, hypoid gear lubricant should be
the housing cover. Build date identification codes are
used for Model 30 axles. The lubricant should have
stamped on the axle shaft tube cover side.
MIL-L-2105C and API GL 5 quality specifications.
The differential case is a one-piece design. The dif
ferential pinion mate shaft is retained with a roll MOPAR® Hypoid Gear Lubricant conforms to both of
pin. Differential bearing preload and ring gear back these specifications.
lash is adjusted by the use of select shims. The shims • The factory fill for the Model 30 axle is SAE 75W
are located between the differential bearing cones gear lubricant.
and case. Pinion bearing preload is set and main • The factory installed lubricant quantity for the
tained by the use of select shims. NON-DISCONNECT TYPE AXLE is 50±1 fluid oz..
PINION GEAR DEPTH MEASUREMENT WITH • The factory installed lubricant quantity for the
GAUGE SET D-115-30 is used when; VACUUM-DISCONNECT TYPE AXLE is 56±1 fluid
• Axle/differential housing is being replaced oz..
J Refer to Group 0, Lubrication and Maintenance for Tighten the upper nut to 75 N»m (55 ft. lbs.)
additional information. torque. Tighten the lower nut to 115 N»m (85 ft. lbs.)
torque.
CAUTION; If the axle is submerged in water, the lu (5) Connect the track bar to the axle bracket and
bricant must be replaced immediately to avoid the install the bolt. Do not tighten at this time.
possibility of premature axle failure. It is important that the springs support the
weight of the vehicle when the track bar is con
nected. If the springs are not at their usual po
DRIVE AXLE ASSEMBLY REPLACEMENT—XJ
sition, the vehicle ride comfort could be affected.
VEHICLES
(6) Install the shock absorber and tighten the bolt
REMOVAL to 19 N-m (14 ft. lbs.) torque.
(1) Raise the vehicle and position support stands (7) Install the stabilizer bar link to the axle
under the frame rails slightly in behind the lower bracket. Tighten the nut to 95 N*m (70 ft. lbs.)
suspension arm frame brackets. torque.
(2) Remove the front wheels. (8) Install the drag link and tie rod to the steering
(3) Remove the brake components and ABS brake knuckles and tighten the nuts to 47 N«m (35 ft. lbs.)
sensor (if equipped). Refer to Group 5, Brakes. torque. Install the steering dampener to the axle
#
(4) On 4WD vehicles, disconnect the axle vent bracket and tighten the nut to 75 N m (55 ft. lbs.)
hose. torque.
(5) On 4WD vehicles, mark the drive shaft yoke (9) Install the brake components and ABS brake
and axle pinion yoke for alignment reference. Discon sensor (if equipped). Refer to Group 5, Brakes.
nect the drive shaft from the axle. (10) On 4WD vehicles, connect the vent hose to the
(6) Disconnect the stabilizer bar link at the axle tube fitting.
bracket. (11) On 4WD vehicles, align the reference marks
(7) Disconnect the shock absorbers from axle and connect the drive shaft to the axle yoke. Tighten
bracket. the U-joint clamp bolts to 19 N»m (14 ft. lbs.) torque.
(8) Disconnect the track bar from the axle bracket. (12) Check differential lubricant and add if neces
(9) Disconnect the tie rod and drag link from the sary.
steering knuckle. Disconnect the steering dampener (13) Install the wheel and tire.
from the axle bracket. (14) Bleed the brakes.
(10) Support the axle with a hydraulic jack under (15) Remove the supports and lower the vehicle.
the differential. (16) Tighten the track bar bolt at the axle bracket
(11) Disconnect the upper and lower suspension to 100 N«m (74 ft. lbs.) torque.
arm from the axle bracket. (17) Check the front wheel alignment.
(12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle. DRIVE AXLE ASSEMBLY REPLACEMENT-YJ
(13) Remove the coil springs from the axle bracket. VEHICLES
INSTALLATION REMOVAL
(1) Raise the vehicle and position support stands
CAUTION: All suspension components that use rub under the frame rails slightly behind the spring
ber bushings should be tightened with the vehicle frame brackets.
at the normal height. It is important to have the (2) Remove the front wheels.
springs supporting the weight of the vehicle when (3) Remove the brake components and ABS brake
the fasteners are torqued. If the springs are not at sensor (if equipped). Refer to Group 5, Brakes.
their normal ride position, vehicle ride comfort (4) Disconnect the axle vent hose and axle shift
could be affected along with premature rubber motor vacuum harness.
bushing wear. Rubber bushings must never be lu (5) Mark the drive shaft yoke and axle pinion yoke
bricated. for alignment reference. Disconnect the drive shaft
from the axle.
(1) Install the springs and retainer clip. Tighten (6) Disconnect the stabilizer bar link at the axle
the screw to 21 N»m (16 ft. lbs.) torque. bracket.
(2) Support the axle on a hydraulic jack under the (7) Disconnect the shock absorbers from axle
differential. Position the axle under the vehicle. bracket.
(3) Raise the axle with a floor jack and align it (8) Disconnect the track bar from the axle bracket.
with the spring pads. (9) Disconnect the tie rod from the steering
(4) Position the upper and lower suspension arm at knuckle. Disconnect the steering dampener from the
the axle bracket. axle bracket.
2 - 22 F R O N T S U S P E N S I O N AND A X L E
J
(10) Support the axle with a hydraulic jack under (13) Install the wheel and tire.
the differential. Raise the axle just enough to relieve (14) Tighten the spring rear pivot bolt/nut to 142
the axle weight from the springs. N*m (105 ft. lbs.) torque. Tighten the spring shackle
(11) Remove the spring U-bolts from the plate bolt/nut to 135 N*m (100 ft. lbs.) torque.
brackets. (15) Tighten the track bar nut at the axle bracket
(12) Loosen RUT DO NOT REMOVE the bolts that to 100 N-m (74 ft. lbs.) torque.
attach the spring rear pivot at the frame rail brack (16) Check the front wheel alignment.
ets. This will allow the springs to pivot without bind
ing on the bushings. LUBRICANT CHANGE
(13) Disconnect shackle from the springs and lower The gear lubricant will drain quicker if the vehicle
the springs to the surface. has been recently driven.
(14) Lower the jack enough to remove the axle. (1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
INSTALLATION differential housing cover.
(3) Remove the differential housing cover and
CAUTION: All suspension components that use rub drain the lubricant from the housing.
ber bushings should be tightened with the vehicle (4) Clean the housing cavity with a flushing oil,
at the normal height. It i s important to have the light engine oil or lint free cloth. Do not use water,
springs supporting the weight of the vehicle when steam, kerosene or gasoline for cleaning.
the fasteners are torqued. If the springs are not at (5) Remove the sealant from the housing and cover
their normal ride position, vehicle ride comfort surfaces. Use solvent to clean the mating surfaces.
could be affected along with premature rubber (6) Apply a bead of MOPAR® Silicone Rubber Seal
bushing wear. Rubber bushings must never be lu ant to the housing cover (Fig. 1). Allow the sealant
bricated. to cure for a few minutes.
(1) Support the axle on a hydraulic jack under the SEALING CONTOUR OF BEAD
differential. Position the axle under the vehicle.
(2) Raise the springs and install the spring shackle
bolts. Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 N»m (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
It is important that the springs support the
nected. If the springs are not at their usual po
sition, the vehicle ride comfort could be affected.
(6) Install the shock absorber and tighten the nut
to 61 N«m (45 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 61 N«m (45 ft. lbs.)
torque.
(8) Install the tie rod to the steering knuckles and
tighten the nuts to 47 N*m (35 ft. lbs.) torque. Install
the steering dampener to the axle bracket and Fig. 1 Typical Housing Cover With Sealant
@
tighten the bolt to 75 N m (55 ft. lbs.) torque. Install the housing cover within 5 minutes af
(9) Install the brake components and ABS brake ter applying the sealant. If not installed the seal
sensor (if equipped). Refer to Group 5, Brakes. ant must be removed and another bead applied.
(10) Connect the vent hose to the tube fitting and (7) Install the cover and any identification tag.
axle shift motor vacuum harness. Tighten the cover bolts in a criss-cross pattern to 47
(11) Align the reference marks and connect the N*m (35 ft. lbs.) torque.
drive shaft to the axle yoke. Tighten the U-joint (8) Refill the differential with MOPAR® Hypoid
clamp bolts to 19 N*m (14 ft. lbs.) torque. Gear Lubricant within 13 mm (1/2 in.) below the fill
(12) Check differential lubricant and add if neces plug hole.
sary. (9) Install the fill hole plug and lower the vehicle.
PINION SHAFT SEAL REPLACEMENT INSTALLATION

(1) Apply a light coating of gear lubricant on the
REMOVAL lip of pinion seal. Install seal with Installer W-147-E
(1) Raise and support the vehicle. and Handle C-4171 (Fig. 4).
(2) Mark the propeller shaft yoke and pinion yoke
for installation alignment reference.
(3) Remove the propeller shaft from the yoke.
(4) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 2).
(5) Mark the positions of the yoke and pinion gear
Fig. 4 Pinion Seal Installation

C-452 J9102-31
(2) Align the installation reference marks and in
Fig. 2 Pinion Yoke Removal stall yoke on the pinion gear with Installer W-162-D.
(3) Tighten the yoke nut to 271 to 298 N*m (200 to
(6) Use Remover W-251 to remove the pinion gear
220 ft. lbs.) torque (Fig. 5).
seal (Fig. 3).
DIFFERENTIAL
W-251
P25180)
J9202-33
Fig. 3 Seal Removal

Fig. 5 Tightening Pinion Shaft Nut
(4) Align the installation reference marks and at
tach the propeller shaft to the yoke.
BRAKE WASHER
SHIELD
RETAINER
TONE HUBAND
WHEEL STEERING BEARING
(ABS) BOLT KNUCKLE ASSEMBLY NUT J9302-43
Fig. 6 Hub, Knuckle and Axle Shaft

(5) Add API grade GL 5 hypoid gear lubricant to (4) Install the hub to knuckle bolts and tighten to
the differential housing, if necessary. 102 N-m (75 ft. lbs.) torque.
(6) Lower the vehicle. (5) Install the hub washer and nut. Tighten the
hub nut to 237 N-m (175 ft. lbs.) torque. Install the
HUB BEARING AND AXLE SHAFT nut retainer and a new cotter pin (Fig. 6).
(6) Install the brake components, refer to Group 5,
REMOVAL
Brakes.
(1) Raise and support the vehicle. (7) Install the wheel and tire.
(2) Remove the wheel and tire. (8) Lower the vehicle.
(3) Remove the brake components from the axle,
refer to Group 5, Brakes. AXLE SHAFT-CARDAN U-JOINT
(4) Remove the cotter pin, nut retainer and axle
hub nut (Fig. 6). DISASSEMBLY
(5) Remove the hub to knuckle bolts (Fig. 6). Re Single cardan U-joints are not serviceable. If defec
move the hub from the steering knuckle and axle tive, they must be replaced as a unit. If the bearings,
shaft. seals, spider or bearing caps are damaged or worn,
(6) Remove the disc brake rotor shield from the replace the complete U-joint.
bearing carrier (Fig. 6).
(7) On disconnect axles, remove vacuum shift mo CAUTION: Clamp only the forged portion of the
tor housing. Refer to Vacuum Disconnect Axle in this yoke in the vise. Also, to avoid distorting the yoke,
section. do not over tighten the vise jaws.
(8) Remove the axle shaft from the housing. Avoid
damaging the axle shaft oil seals in the differen (1) Remove the bearing cap retaining snap rings
tial. (Fig. 7).
It can be helpful to saturate the bearing caps
INSTALLATION with penetrating oil prior to removal.
(1) Thoroughly clean the axle shaft (Fig. 6) and ap (2) Locate a socket that is larger in diameter than
ply a thin film of Mopar Wheel Bearing Grease to the bearing cap. Place the socket (receiver) against
the shaft splines, seal contact surface and hub bore. the yoke and around the perimeter of the bearing cap
(2) Install the axle shaft into the housing and dif to be removed. Locate a socket that is smaller in di
ferential side gears. Avoid damaging the axle shaft ameter than the bearing cap. Place the socket (driv
oil seals in the differential. er) against the opposite bearing cap. Position the
(3) Install the hub bearing and brake dust shield yoke with the sockets in a vise (Fig. 8).
to the knuckle.
BEARING (2) Inspect the yokes for distortion, cracks and

BEARING CAP worn bearing cap bores.
CAP
(3) Replace the complete U-joint if any of the com
SPINDLE ponents are defective.
YOKE
SHAFT
YOKE ASSEMBLY
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket wrench in a
BEARING' vise.
CAP
BEARING (4) Compress the vise to force the bearing caps into
SNAP CAP the yoke. Force the caps enough to install the retain
RINGS
ing clips.
J8902-15 (5) Install the bearing cap retaining clips.
(6) Install the axle shaft, refer to Hub Bearing and
Fig. 7 Axle Shaft Outer U-Joint Axle Shaft installation.
LARGE-
DIAMETER VACUUM DISCONNECT AXLE—YJ VEHICLES
SOCKET
WRENCH
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
• Check valve
• Vacuum harness (Fig. 9, 10)
SMALL- CHECK
DIAMETER VALVE
SOCKET
WRENCH
J8902-16
Fig. 8 Yoke Bearing Cap Removal

(3) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(4) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(5) Repeat the above procedure for the remaining
bearing cap. CONTROL
SWITCH
(6) Remove the remaining bearing cap, bearings,
ON
seals and spider from the propeller shaft yoke. AIR' TRANSFER
VENT CASE
FILTER
CLEANING AND INSPECTION AXLE
SHIR
(1) Clean all the U-joint yoke bores with cleaning MOTOR J9202-55
solvent and a wire brush. Ensure that all the rust
and foreign matter are removed from the bores. Fig. 9 Vacuum Control System
Fig. 10 Vacuum Hose Routing

Refer to Group 21, Transmissions for additional in
formation.
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
TWO-WHEEL DRIVE OPERATION DIAGNOSIS

FOUR-WHEEL DRIVE
INDICATOR LIGHT WILL
N O T GO O U T W H E N
TRANSFER CASE SELECTOR
IS M O V E D FROM 4H TO
2H POSITION.
1
YES
START E N G I N E DEPRESS BRAKE TEST COMPLETE

INSPECT INDICATOR PEDAL. PLACE TRANSFER
RAISE VEHICLE S O ALL SWITCH A N D W I R I N G O N CASE SELECTOR IN 2H POSITION
FOUR WHEELS ARE SHIFT M O T O R H O U S I N G A N D T R A N S M I S S I O N IN
FOR D A M A G E A N D DRIVE (AUTOMATIC)O R FIRST

FREE T O ROTATE.
SHORT-CIRCUIT. G E A R ( M A N U A L ) . EASE OFF FROM
REPAIR A S NECESSARY. B R A K E A N D LET W H E E L S ROTATE

SLOWLY.
FRONT DRIVE FRONT DRIVE
SHAFT DOES SHAFT ROTATES.

N O T ROTATE.
INSPECT TRANSFER
FOUR-WHEEL DRIVE CASE LINKAGE.
INDICATOR LIGHT
R E M A I N S O N
CHECK TRANSFER
CASE. REPAIR
PLACE T R A N S M I S S I O N A S NECESSARY.
IN NEUTRAL. TEST F O R V A C U U M
IN V A C U U M HOSE
t THAT C O N N E C T S
I N B O A R D SHIFT
TO
D I C O N N E C T T H E M O T O R PORT.
SHIFT M O T O R V A C U U M (VACUUM S H O U L D BE
HOSES. BETWEEN 10-20 IN. HG.)
V A C U U M O K
N O V A C U U M
O R L O W V A C U U M .
=3=1.
STOP E N G I N E I
INSPECT
V A C U U M SUPPLY H O S E
INTAKE M A N I F O L D
C O N N E C T I O N ,
r
C O N N E C T A V A C U U M
TRANSFER CASE V A C U U M SWITCH
PUMP T O THE I N B O A R D
C O N N E C T I O N , V A C U U M RESERVOIR,
SHIFT M O T O R PORT.
A N D SHIFT SYSTEM V A C U U M HOSES
A P P L Y 15 I N . H G
FOR PROPER C O N N E C T I O N , RESTRICTION,
V A C U U M A N D ROTATE
AIR LEAKS, A N D D A M A G E . REPAIR O R REPLACE
RIGHT W H E E L
A S NECESSARY.
I R O N T A X L E FRONT AXLE
DISCONNECTS DOES N O T
DISCONNECT.
INSPECT V A C U U M
H O S E S FOR AIR LEAKS, KINKS, ETC.
REPAIR A S NECESSARY. REMOVE SHIFT M O T O R
H O U S I N G COVER. C O N N E C T
V A C U U M PUMP TO
SHIFT M O T O R PORT. FRONT AXLE
REPLACE SHIFT M O T O R WILL N O T DISCONNECT.
IF A R M A T U R E DOES
N O T MOVE IN A N D O U T
FREELY.
REMOVE SHIFT M O T O R H O U S I N G
COVER. INSPECT SHIFT FORK,
COLLAR, A N D AXLE SHAFTS.
REPAIR O R REPLACE A S
J9002-95 NECESSARY.
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)
FOUR-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR

LIGHT DOES NOT LIGHT WHEN
TRANSFER CASE SELECTOR IN
4H OR 4L POSITION.
RAISE VEHICLE SO ALL FOUR

WHEELS ARE FREE TO ROTATE.
START ENGINE, DEPRESS BRAKE PEDAL.

PLACE TRANSFER CASE SELECTOR IN 4H
POSITION A N D TRANSMISSION LEVER IN
DRIVE (AUTOMATIC) OR IN FIRST GEAR
(MANUAL) TO CONFIRM TRANSFER CASE
ENGAGEMENT IN 4H. LET WHEELS
ROTATE SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT TURNS.
NOT ROTATE.
INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

CHECK VACUUM PLACE TRANSMISSION FRONT AXLE
CASE LINKAGE. CONNECTS. LEVER IN NEUTRAL DOES NOT
SHIFT SYSTEM
FOR PROPER POSITION. CONNECT.
OPERATION.
CHECK TRANSFER FOUR-WHEEL DRIVE
CASE. REPAIR AS INDICATOR LIGHT
NECESSARY. DOES NOT LIGHT. REMOVE VACUUM HOSES
FROM AXLE SHIFT
MOTOR PORTS.
INSPECT FWD INDICATOR

SWITCH, WIRING, A N D START ENGINE. TEST FOR VACUUM
LAMP FOR DAMAGE. AT HOSE REMOVED FROM OUT
REPAIR AS NECESSARY. BOARD PORT O N SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.
N O VACUUM STOP ENGINE VACUUM OK

OR LOW VACUUM. K
CONNECT A VACUUM PUMP

INSPECT INTAKE MANIFOLD TO THE OUTBOARD
VACUUM SUPPLY HOSE CONNECTION, SHIFT MOTOR PORT.
TRANSFER CASE VACUUM SWITCH APPLY 15 INCHES HG. VACUUM
CONNECTION, VACUUM RESERVOIR, A N D SHIFT AND ROTATE LEFT WHEEL.
SYSTEM VACUUM HOSES FOR PROPER CONNECTION,
RESTRICTION, LEAKS, A N D DAMAGE.
REPAIR OR REPLACE AS NECESSARY.
FRONT AXLE FRONT AXLE

N O VACUUM CONNECTED. DOES NOT
CONNECT.
CHECK TRANSFER CASE

VACUUM SWITCH. REPLACE INSPECT VACUUM HOSES
OR REPAIR IF SWITCH FOR LEAKS, KINKS, ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR AS NECESSARY. HOUSING COVER. CONNECT
MOVE OR BINDS. VACUUM PUMP TO
SHIFT MOTOR PORT.
REPLACE SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN A N D OUT
FREELY.
REMOVE SHIFT MOTOR HOUSING t

COVER. INSPECT SHIFT FORK,
FRONT AXLE
COLLAR, A N D AXLE SHAFTS.
WILL NOT CONNECT.
REPAIR OR REPLACE AS
NECESSARY.
J9002-96
SHIFT MOTOR-REMOVAUDISASSEMBLY (4) Install the shift motor housing gasket and
(1) Disconnect the vacuum and wiring connector cover. Ensure the shift fork is correctly guided
from the shift housing. into the shift collar groove.
(2) Remove the shift motor housing cover, gasket (5) Install the shift motor housing shield and at
and shield from the housing (Fig. 11). taching bolts. Tighten the bolts to 11 N»m (101 in.
lbs.) torque.
SHIR
COLLAR (6) Add 148 ml (5 ounces) of API grade GL 5 hy
poid gear lubricant to the shift motor housing
through the fill plug.
INTERMEDIATE AXLE SHAFT-REMOVAL/

DISASSEMBLY
Service to the Disconnect axle seals and bearing re
quire the use of Tool Set 6288 (J34659) and Seal In
staller 6228.
SHIFT (1) Remove the vacuum motor housing. Refer to
FORK SHIFT Shift Motor Removal in this section.
MOTOR (2) Remove the differential housing cover and
HOUSING
drain the lubricant.
J9002-51 (3) Push the intermediate axle shaft toward the
center of the vehicle. Remove the C-lock from the in
Fig. 11 Shift Motor Housing and Shift Collar termediate shaft and side gear in the differential
(3) Remove the E-clips from the shift motor hous (Fig. 13).
ing and shaft. Remove shift motor and shift fork
from the housing (Fig. 12).
INDICATOR
SWITCH
VACUUM
PORTS
J9202-54 RETAINING
CLIP ^
Fig. 12 Vacuum Shift Motor Components

(4) Remove the O-ring seal from the shift motor J8902-18
shaft.
(5) Clean and inspect all components. If any com Fig. 13 Intermediate Axle Shaft C-clip Removal
ponent is excessively worn or damaged, it should be
(4) Remove the outer axle shaft. Refer to Hub
replaced.
Bearing and Axle Shaft in this section.
ASSEMBL Y/INSTALLA TION (5) Remove shift collar and intermediate axle
(1) Install a new O-ring seal on the shift motor shaft.
shaft. (6) Remove the inner axle shaft seal from the shift
(2) Insert the shift motor shaft through the hole in motor housing (Fig. 14).
the housing and shift fork. The shift fork offset (7) Remove the intermediate axle shaft bushing
should be toward the differential. (Fig. 15).
(3) Install the E-clips on the shift motor shaft and
housing.
(3) Apply a light film of oil to the inside lip of the

J
new axle shaft seal.
(4) Install the inner axle seal (Fig. 17, 18).
The axle shaft seal primary installation tool
6228-1 will only force the seal partially into the
axle shaft tube bore. The axle shaft seal second
ary installation tool 6228-3 must be used to com
pletely seat the seal in the axle shaft tube bore.
After seal installation, inspect that the seal is
NOT distorted or cocked in the tube.
TOOL TOOL TOOL
AXLE T U B E POSITION
7920 7919 7918
FOR OPEN-END
(J-34659-5) (J-34659-4) (J-34659-3)
WRENCH
SEAL
J9002-1
Fig. 14 Axle Shaft Inner Seal Removal HOLE
SHIFT M O T O R LOCATION
H O U S I N G OPENING FOR OPEN-END
WRENCH
BEARING
TOOL
7918
TOOL \ (J-34659-3)
TOOL 7919
6228-1 SEAL 6228-2 (J-34659-4) N U T J9002-4
Fig. 17 Primary Installation of Seal (Step One)

AXLE T U B E POSITION
TOOL TOOL FOR OPEN-END
TOOL
7919 7918 WRENCH
7916
(J-34659-1) (J-34659-4) NUT (J-34659-3) J 9 202_ 1 0
Fig. 15 Bushing Removal Tool Installed

HOLEllllBte
ASSEMBL Y/INSTALLA TION
(1) Position the bushing on installation tool. Seat
the bushing in the housing bore (Fig. 16).
SHIFT MOTOR
HOUSING OPENING
TOOL
7918
TOOL
(J-34659-3)
TOOL TOOL 7919
51 mm (2 in.)
6228-3 SEAL 6228-2 (J-34659-4) NUT J9002-6
Fig. 18 Secondary Installation of Seal (Step Two)

(5) Insert the intermediate axle shaft into the dif
ferential side gear.
(6) Install the C-lock in the axle shaft and side
TOOL
gear.
TOOL TOOL I 7 9 1 8
(7) Install the shift collar on the splined end of the
intermediate axle shaft.
7919 I (J-34659-3) (8) Lubricate the splined end of the intermediate
7 9 1 7
J9002-10
BEARING (J-34659-2) (J-34659-4) NUT
axle shaft with multi-purpose lubricant (Fig. 19).
Fig. 16 Intermediate Shaft Bushing Installation
CAUTION: Apply all-purpose lubricant to the axle
(2) Clean the inside perimeter of the axle shaft
shaft splines to prevent damage to the seal during
tube with fine crocus cloth.
axle shaft installation.
AXLE SHIFT MOTOR

TUBE HOUSING
J 9 0 0 2 7
COLLAR -
Fig. 19 Shift Collar Installation

(8) Insert the axle shaft into the tube. Engage the
splined-end of the shaft with the shift collar. Refer to
Hub Bearing and Axle Shaft in this section.
(9) Install the vacuum motor housing. Refer to
Shift Motor Installation in this section. Fig. 20 Upper Ball Stud Nut Removal
(10) Install the differential cover and add lubri
cant. Refer to Lubricant Change in this section.
S T E E R I N G K N U C K L E AND B A L L S T U D S
Ball Stud service procedures below require removal
of the hub bearing and axle shaft. Removal and in
stallation of upper and lower ball stud requires use
of Tool Kit 6289 (J34503-A).
KNUCKLE REMOVAL
(1) Remove hub bearing and axle shaft refer to the
Removal procedure.
(2) If necessary, disconnect the tie-rod or drag link
end from the steering knuckle arm. Remove the ABS
sensor wire and bracket from knuckle.
(3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts (Fig.
20).
(4) Strike the steering knuckle with a brass ham
mer to loosen. Remove knuckle from axle tube yokes
(Fig. 21). KNUCKLE BALL STUD J9302-16
UPPER BALL STUD REPLACEMENT Fig. 21 Steering Knuckle Removal/Installation

(1) Position tools as shown to remove and install (3) Install and tighten the top retaining nut to 101
ball stud (Fig. 22). N*m (75 ft. lbs.) torque (Fig. 25). Install new cotter
pin.
LOWER BALL STUD REPLACEMENT
(1) Position tools as shown to remove and install (4) Install the Hub Bearing and Axle Shaft accord
ball stud (Fig. 2 3 ) . ing to the installation procedure.
(5) If necessary, reconnect the tie-rod or drag link
KNUCKLE INSTALLATION end onto the steering knuckle arm. Install the ABS
(1) Position the steering knuckle on the ball studs. sensor wire and bracket to the knuckle, refer to
(2) Install and tighten the bottom retaining nut to Group 5, Brakes.
135 N-m (100 ft. lbs.) torque (Fig. 24). Install new
cotter pins.
32 FRONT SUSPENSION AND AXLE
7910
J9519-1
7910
J9519-1
7903
J34503-1
7907
J34503-3 7904
J34503-2
REMOVAL INSTALLATION
J9302-37
Fig. 22 Upper Ball Stud Remove/Install
7904
J34503-2
7907
J34503-3
7908
J34503-4
7903
J34503-1
7910 7910
J9519-1
J9519-
REMOVAL INSTALLATION J9302-38
Fig. 23 Lower Ball Stud Remove/Install

J
Fig. 26 Bearing Cap Identification

(3) Position Spreader W-129-A with the tool dowel
pins seated in the locating holes (Fig. 27). Install the
holddown clamps and tighten the tool turnbuckle fin
ger-tight.
Fig. 27 Spread Differential Housing

(4) Install a pilot stud at the left side of the differ
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 27) and zero the indicator.
CAUTION: Do not spread over 0.38 mm (0.015 in). If

Fig. 25 Upper Ball Stud Nut Installation the housing i s over-separated, it could be distorted
or damaged.
AXLE BUSHING REPLACEMENT
Refer to Axle Bushing Replacement in the Front (5) Separate the housing enough to remove the
Suspension section. case from the housing. Measure the distance with the
dial indicator (Fig. 27).
DIFFERENTIAL REMOVAL
To service the differential the axle shafts must be (6) Remove the dial indicator.
removed. Refer to the removal procedures in this (7) Pry the differential case loose from the hous
Group. ing. To prevent damage,, pivot on housing with the
(1) Note the installation reference letters end of the pry bar against spreader (Fig. 28).
stamped on the bearing caps and housing ma (8) Remove the case from housing. Mark or tag
chined sealing surface (Fig. 26). bearing cups indicating which side they were re
(2) Remove the differential bearing caps. moved. Remove spreader from housing.
DIFFERENTIAL PRY BAR (2) Install the inner axle seal on Tool 6228-1 (Fig.
30).
(3) Thread the reverse side of Installer 6228-1
tightly onto the threaded rod tool (Fig. 30).
(4) Press the seals into position.
DIFFERENTIAL
HOUSING
LOCATION
FOR O P E N - E N D
WRENCH
J9302-18
Fig. 28 Differential Removal TOOL

NUT 7918
INNER AXLE SHAFT OIL SEAL REPLACEMENT TOOL,
(J-34659-3)
TOOL
7919
SELECT TRAC 6228-1
(J-34659-4)
(REVERSED) J9202-9
(1) Remove the inner axle shaft seals with a pry
bay. Fig. 30 Left Side Seal Installation
(2) Install oil seals with Adapter D-112-4, D-112-5
and Turnbuckle D-112 (Fig. 29). Tighten tool until DIFFERENTIAL DISASSEMBLY
disc bottoms in housing. (1) Remove the bearings from the differential case
with Press C-293-PA, Plug C-293-3, Adapter
ADAPTER TOOL
A N D SEAL
C-293-39 (Fig. 31).
Place adapter rings so they do not damage the
bearing cage.
(2) Remove bearing shims from case hubs and
mark them (with hub identity) for assembly refer
ence. Record the thickness of the shims.
(3) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
bolts. Tap the ring gear with a rawhide mallet and
remove (Fig. 32).
(4) Use a drift to remove the pinion gear mate
shaft lock pin (Fig. 32).
(5) Remove the mate shaft with a drift and ham
mer (Fig. 34).
(6) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 35).
(7) Remove the differential side gears and thrust
INSTALLATION
SPREADER
washers.
TOOL (8) Remove the case from the vise.
D-112/D-112-44
J9002-17 PINION REMOVAL/DISASSEMBLY
(1) Remove the pinion yoke nut and washer. Use
Fig. 29 Axle Seal Installation
COMMAND TRAC-LEFT-SIDE pinion yoke (Fig. 36).
(1) Remove the inner axle shaft seals with a pry (2) Remove the pinion gear seal with a slide ham
bar. mer or pry out with bar.
J
ADAPTERS
Fig. 33 Mate Shaft Lock Pin Removal
Fig. 31 Differential Bearing Removal
Fig. 34 Mate Shaft Removal

(8) Remove the inner bearing from the pinion with
Puller C-293-PA and Adapter C-293-39 (Fig. 41).
bearing cage.
(9) Remove the oil slinger (if equipped) from the
Fig. 32 Ring Gear Removal pinion gear shaft.
(3) Remove the pinion gear from housing (Fig. 37).
Catch the pinion with your hand to prevent it from CLEANING/INSPECTION
falling and being damaged. Wash differential components with cleaning sol
(4) Remove the pinion preload shims (Fig. 38). vent and dry with compressed air. Do not steam
(5) Remove oil slinger, front bearing. clean the differential components.
(6) Remove the front pinion bearing cup with Re Wash bearings with solvent and towel dry, do not
mover D-147 and Handle C-4171 (Fig. 39). dry with compressed air. Cup and bearing must be
(7) Remove the rear bearing cup from housing replaced as a matched set only.
(Fig. 40). Use Remover D-149 and Handle C-4171. Clean the axle shaft tubes with a stiff wire or a
clean cloth.
Inspect for;
THRUST RAWHIDE
WASHER
MATE GEAR SIDE G E A R J9203-61
Fig. 35 Pinion Mate Gear Removal Fig. 37 Remove Pinion Gear
C-452 J9102-31
Fig. 36 Pinion Yoke Removal

• Smooth appearance with no broken/dented surfaces
on the bearing rollers or the roller contact surfaces.
• Bearing cups must not be distorted or cracked. 1-74
• Machined surfaces should be smooth and without
any raised edges. Fig. 38 Pinion Bearing Preload Shims
• Raised metal on shoulders of cup bores should be • Pinion yoke for cracks, worn splines, pitted areas,
removed with a hand stone. and a rough/corroded seal contact surface. Repair or
• Wear and damage to pinion gear mate shaft, pin replace as necessary.
ion gears, side gears and thrust washers. Replace as • Preload shims for damage and distortion. Install
a matched set only. new shims if necessary.
• Ring and pinion gear for worn and chipped teeth.
• Ring gear for damaged bolt threads. Replaced as a
matched set only.
SPECIAL
TOOL
C-293-PA
Fig. 39 Front Bearing Cup Removal Fig. 41 Inner Bearing Removal

I f replacement gears and thrust washers were
installed, i t i s not necessary to measure the gear
backlash. Correct f i t is due to close machining
tolerances during manufacture.
J9302-23
Fig. 40 Rear Bearing Cup Removal

DIFFERENTIAL ASSEMBLY
ASSEMBLY
(1) Install the following components in the differ
ential case (Fig. 42). Fig. 42 Mate Shaft Pin Installation
• Differential side gears and thrust washers
• Pinion gears and thrust washers (3) Invert the differential case and start two ring
• Pinion gear mate shaft (align holes in shaft and gear bolts. This will provide case-to-ring gear bolt
case) hole alignment.
(2) Install and seat the lock pin in the differential (4) Install new ring gear bolts and alternately
case and mate shaft with a punch and hammer (Fig. tighten to 61-81 N*m (45-60 ft. lbs.) torque (Fig. 43).
42). Peen metal part of case over pin in two places.
TORQUE PINION
WRENCH N O T A M A C H I N E D SURFACE
BUTTON
END
RING GEAR
BOLT
RING
GEAR
J9302-36
J9202-77
Fig. 45 Pinion Gear Head

Fig. 43 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
poid gear lubricant. (service). The slinger is placed between the inner
pinion bearing cone and gear head (Fig. 46). The
PINION GEAR DEPTH INFORMATION
shim pack is placed under the inner (rear) bearing
Gears are supplied as matched sets only. The iden
tifying numbers for the ring and pinion gear are cup. To change the pinion adjustment, shims are
etched into the face of each gear (Fig. 44). A plus ( + ) available in thicknesses of 0.003, 0.005, and 0.010
number, minus (-) number or zero (0) is etched into inch. If equipped, the oil slinger or baffle must
the face of the pinion gear. This number is the be measured and the thickness included with
amount (in thousandths of an inch) the depth varies the total shim pack.
from the standard depth setting of 2.250 inches (57.1 New gear set: note the depth variance etched
mm) for Model 30 axles. The standard depth provides into both the original and the replacement pin-
the best teeth contact pattern. DRIVE
PINION
DRIVE P I N I O N
BEARING
PRODUCTION GEAR DEPTH
PRELOAD
NUMBERS VARIANCE
SPACER/SHIM
DRIVE
PINION GEAR
DEPTH
SHIM
G E A R MATCHING N U M B E R
(SAME A S R I N G G E A R N U M B E R ) J9003-100
Fig. 44 Pinion Gear ID Numbers

THE BUTTON END ON THE PINION GEAR HEAD DIFFERENTIAL-
BEARING
IS NO LONGER A MACHINED-TO-SPECIFICATIONS SHIM J9002-32
SURFACE. DO NOT USE THIS SURFACE FOR PIN
ION DEPTH SET-UP OR CHECKING (Fig. 45). Fig. 46 Shim Locations
J F R O N T S U S P E N S I O N AND AXLE 2 - 39
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance -4 -3 -2 -1 0 +1 +2 +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 +0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 +0.CW6 +0.005 + 0.004 +0.003 +0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 +0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
ion gear. Add or subtract thickness of original
shims to compensate for difference in depth
variances. Refer to Depth Variance charts.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or mi
nus amount needed.
For example, if old pinion is plus ( + ) 1 and the
new pinion is minus (-) 3, intersecting figure is
( + )0.004 inch (0.10mm). Add this amount to the
original shim. Or if the old pinion is (-) 3 and the
new pinion is (-) 2, intersecting figure is (-)0.001 inch
(0.025mm). Subtract this amount from original shim.
Refer to the Pinion Gear Depth Variance Chart.
DIFFERENTIAL AND PINION MEASUREMENT WITH

GAUGE SET D-115-30
DIFFERENTIAL ZERO END PLA Y
MEASUREMENT
(1) Place Master Differential Bearing D-134
(D-348) on the case hubs (Fig. 47). J9202-43
(2) Install a pilot stud at the right side of housing.
Fig. 47 Master Bearing Tools On Hubs
Attach Dial Indicator to the pilot stud. Load indica
tor plunger against the back of the ring gear (Fig. thickness will be determined during the ring
48). gear backlash adjustment.
(3) Insert a small pry bar between the bearing cap (5) Remove indicator and pilot stud.
and left side of differential case. Pry the case as far
PINION GEAR DEPTH MEASUREMENT
as possible to right side (Fig. 48). Zero the dial indi
cator pointer. The following gear depth measurement and adjust
(4) Pry the case to left side and record the travel ment procedure involves using Gauge Set D-115-30
distance. (Fig. 49).
The measurement above is the shim thickness (1) Insert Master Pinion Block D-138 into the pin
necessary for case zero end-play. The total ion gear bore (Fig. 50).
J
Fig. 50 Pinion Block Tool Inserted In Shaft Bore
D-138 D-115-1 D-115 Fig. 51 Gauge Tools In Housing
J9202-30
Fig. 49 Pinion Gear Depth Gauge Tool Set 0-115-30

(2) Place Disc D-115-4 on Arbor D-115-3 and posi
tion in the bearing cradles (Fig. 51).
(3) Place Pinion Height Block D-115-1 on top of
master pinion block tool and against arbor tool (Fig.
52).
(4) Firmly place Scooter Block and Dial Indicator Fig. 52 Pinion Height Block Tool Against Arbor
D-115 on the lowest step of pinion height block tool
serving indicator. Record the longest travel distance,
(Fig. 53). Zero the dial indicator pointer.
whether inward (-) or outward ( + ), indicated by the
(5) Move the gauge block toward the arbor until pointer.
the indicator plunger contacts the arbor tool (Fig.
53). Slide the gauge block across the arbor while ob-
BLOCK TOOL A N D (9) Install the pinion front bearing cup with In
DIAL INDICATOR staller D-144 and Handle C-4171 (Fig. 55).
TOOL
SPECIAL T O O L
P I N I O N HEIGHT SPECIAL
D-144
BLOCK TOOL TOOL
C4171
Fig. 53 Pinion Gear Depth Measurement

The distance indicated, plus or minus variance
etched in the gear is required thickness for Fig. 55 Pinion Front Bearing Cup Installation
depth shims. (10) Install the rear bearing (and slinger if used)
(6) Measure the thickness of each depth shim with on the pinion gear with Installer W-262 until com
a micrometer and combine the shims necessary for pletely seated (Fig. 56).
total required pack thickness. Include oil slinger or
baffle thickness with the total shim pack thick
ness. PRESS
(7) Remove the measurement tools from the differ
ential housing.
PINION GEAR A S S E M B L Y / I N S T A L L A T I O N
(8) Place the shims (and baffle if equipped) in the INSTALLATION
TOOL
pinion gear rear bearing bore. Install the bearing cup
with Installer D-146 and Driver Handle C-4171 (Fig.
54). Ensure cup is correctly seated.
DRIVE
SPECIAL TOOL PINION GEAR
D-146 SHAFT
REAR BEARING'
OIL
SUNGER
DRIVE
PINION GEAR J9302-68
Fig. 56 Pinion Rear Bearing Installation

(11) Assemble preload shims onto pinion and in
stall the pinion gear in housing (Fig. 57).
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer
W-162-D and Wrench C-3281 (Fig. 58).
(13) Tighten the yoke nut to 271 to 298 N-m (200
SPECIAL to 220 ft. lbs.) torque.
TOOL
C-4171 J9302-7 (14) Check bearing preload torque with an inch
pound torque wrench (Fig. 59). The torque necessary
Fig. 54 Pinion Rear Bearing Cup Installation to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N-m (10 to 20 in. lbs.).
- 42 FRONT SUSPENSION AND AXLE
PRELOAD
SHIMS
SHOULDER
REAR
BEARING
PINION
GEAR
J9302^74 J9303-10
Fig. 57 Pinion Bearing Preload Shims Fig. 59 Check Pinion Gear Torque
SPECIAL DIFFERENTIAL If the preload torque is not within the specified tol
TOOL HOUSING erance, correct the shim thickness accordingly (Fig.
W-162-D 60);
• Increase the preload torque, decrease the shim
thickness
• Decrease the preload torque, increase the shim
thickness
BEARING
PRELOAD
S H I M PACK
SPECIAL
TOOL
C-3281
PINION
LOCATING
S H I M PACK
J9302-24
Fig. 58 Pinion Yoke Installation

New Bearings — 2 to 5 N*m (20 to 40 in. lbs.).
DIFFERENTIAL BEARING
S H I M PACKS RY660
Fig. 60 Shim Locations

J
(15) Remove the pinion yoke nut and washer. Use (2) Install a pilot stud at the left side of housing.
Remover C-452 and Wrench C-3281 to remove the Attach Dial Indicator to housing. Load the indicator
pinion yoke (Fig. 61). plunger against the back of the ring gear (Fig. 63).
Ensure ring and pinion gear teeth are tightly
meshed. Zero the indicator.
C-452 J9102-31

lip of pinion seal. Install the new seal (Fig. 62) with
Installer W-147-E and Handle C-4171
Fig. 63 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. 63). Zero the dial indi
cator pointer.
(4) Repeat the measurement several times to check
consistency. Record the travel distance.
The measurement above shows shim thickness
necessary to eliminate ring gear backlash. Sub
tract this thickness from case zero end-play
shim thickness (Fig. 64). The shims must be
placed at the ring gear side between the case
and bearing.
(5) Remove indicator and pilot stud.
(6) Remove the differential case from housing.
(7) Remove the master bearing tools from the dif
ferential case hubs.
Fig. 62 Pinion Seal Installation (8) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear
(17) Install the yoke with Installer W-162-D and ing on the hub with Bearing Installer C-3716-A and
Wrench C-3281. Driver Handle C-4171 (Fig. 65).
(18) Install a new yoke nut and tighten to 271 to (9) Position the remaining zero end-play shims on
298 N*m (200 to 220 ft. lbs.) torque. hub at opposite side of case. Include an additional
0.015 in. (0.38 mm) thick shim on this hub. This will
DIFFERENTIAL SHIM PACK MEASUREMENT AND
provide the required differential bearing preload
ADJUSTMENT
torque.
(1) Place Master Differential Bearing D-134
(10) Install bearings on hubs with Installer
(D-348) on the case hubs.
C-3716-A and Handle C-4171 (Fig. 65).
J
For Example: SPECIAL TOOL
W-129-A
DIAL
Indicator Reading LESS PINION 0.085 in. total INDICATOR
Indicator Reading WITH PINION 0.055 in. total -
BALANCE OF SHIM PACK 0.030 in. total—.
Place BALANCE of shims at opposite

side of ring gear
ADD an additional 0.015 in. shim to opposite side

of ring gear for bearing preload
Ring Gear Side (Flange Side) 0.055 in.«. J9302-27
Opposite Side 0.030 in. - Fig. 66 Spread Differential Housing

stud. Load the indicator plunger against the opposite
Opposite Side Preload 0.015 in. side of the housing (Fig. 66) and zero the indicator.
Total Opposite Side 0.045 in. J9302-65 CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over-separated, it could be distorted
Fig. 64 Shim Pack Calculations or damaged.
(3) Separate the housing enough to install the case

in the housing. Measure the distance with the dial
indicator (Fig. 66).
(4) Remove the dial indicator.
(5) Install case in the housing. Tap the differential
case to ensure the bearings are fully seated (Fig. 67).
Remove the spreader.
SPECIAL TOOL
C-4171 RAWHIDE
HAMMER
SPECIAL T O O L
C-3716-A
J9302-21
Fig. 65 Differential Bearing Installation

(11) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
DIFFERENTIAL INSTALLATION
J9302-19
pins seated in the locating holes (Fig. 66)^ Install the
holddown clamps and tighten the tool turnbuckle fin Fig. 67 Differential Installation
ger-tight.
(6) Install the bearing caps at their original loca

tions (Fig. 68). Tighten the bearing cap bolts to 77
N-m (57 ft. lbs.) torque.
Fig. 68 Differential Bearing Cap Reference Letters

J9302-28
BACKLASH AND CONTACT PATTERN ANALYSIS
(1) Rotate assembly sevei al revolutions to seat Fig. 70 Backlash Shim Adjustment
bearings. Measure backlash at three equally spaced The ring gear teeth contact patterns will show if
locations around the perimeter of the ring gear with the pinion gear depth shim(s) have the correct thick
a dial indicator (Fig. 69). ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main
tained within the specified limits until the correct
tooth contact patterns are obtained.
(2) Apply a thin coat of hydrated ferric oxide to the
drive and coast side of the ring gear teeth.
(3) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This action will produce distinct contact pat
terns on both the drive side and coast side of the ring
gear teeth.
(4) Note patterns in compound. Refer to (Fig. 71)
for interpretation of contact patterns and adjust ac
cordingly.
FINAL ASSEMBLY
Fig. 69 Ring Gear Backlash Measurement (1) Install the axle shafts. Refer to Axle Shaft In
The ring gear backlash must be within 0,005 - stallation in this Group.
0,009 inch (0.12 - 0.23 mm). It cannot vary more (2) Scrape the residual sealant from the housing
than 0.002 inch (0.05 mm) between the points and cover mating surfaces. Clean the mating sur
checked. faces with mineral spirits. Apply a bead of MOPAR®
If backlash must be adjusted, transfer shims from Silicone Rubber Sealant on the housing cover (Fig.
one side of carrier to the other side. Adjust the back 72). Allow the sealant to cure for a few minutes.
lash accordingly (Fig. 70). DO NOT INCREASE Install the housing cover within 5 minutes af
THE TOTAL SHIM P A C K THICKNESS, EXCES ter applying the sealant. If not installed the seal
SIVE BEARING PRELOAD A N D DAMAGE ant must be removed and another bead applied,
WILL OCCUR. (3) Install the cover on the differential with the at
If the mesh and backlash steps have been followed taching bolts. Install the identification tag. Tighten
in the procedures above, good gear teeth contact pat the cover bolts to 47 N-m (35 ft. lbs.) torque.
terns should exist.
DRIVE SIDE C O A S T SIDE

O F RING O F RING
GEAR T E E T H GEAR T E E T H
DESIRABLE C O N T A C T P A T T E R N .
P A T T E R N S H O U L D BE C E N T E R E D
O N T H E DRIVE S I D E O F T O O T H .
H E E ^ ^ ^ ^ ^ ^ ^ ^ O E T O ^ ^ ^ ^ ^ ^ ^ ^ ^ E L
P A T T E R N S H O U L D BE C E N T E R E D O N
THE COAST SIDE O F T O O T H ,
B U T MAY BE S L I G H T L Y T O W A R D
T H E T O E . T H E R E S H O U L D ALWAYS
BE S O M E CLEARANCE B E T W E E N
CONTACT PATTERN AND T O P O F
THE T O O T H .
R I N G GEAR BACKLASH CORRECT.

T H I N N E R P I N I O N GEAR D E P T H
SHIM REQUIRED.
R I N G GEAR BACKLASH CORRECT.

T H I C K E R P I N I O N GEAR D E P T H
SHIM REQUIRED.
P I N I O N GEAR D E P T H S H I M
CORRECT. D E C R E A S E R I N G
GEAR B A C K L A S H .
CORRECT I N C R E A S E RING
§3
GEAR BACKLASH.
J9003-24
Fig. 71 Gear Tooth Contact Patterns

FRONT SUSPENSION AND AXLE 2 -47
CAUTION: Overfilling the differential can result in SEALING CONTOUR OF BEAD

the lubricant foaming and overheating.
(4) Refill the differential housing with the speci

fied quantity of MOPAR® Hypoid Gear Lubricant.
(5) Install the fill hole plug and tighten to 34 N-m
Fig. 72 Typical Housing Cover With Sealant
AXLE SPECIFICATIONS
MODEL 30 FRONT AXLE
Axle Type Hypoid Differential Bearing

Preload Shim 0.015 in. 0.38 mm
Application XJ/YJ
Differential Side
Gear-to-Case Clearance 0.000-0.007 in. 0.00-0.18 mm
Ring Gear Diameter 7.125 in. (18.09 cm)
Ring Gear Backlash 0.005-0.008 in. 0.12-0.20 mm
Lubricants MOPAR Gear Lubrication or
Equivalent SAE 75W-90, Drive Pinion Gearshaft
API Grade GL-5, MIL-L-2105C Bearing Break-Away
Preload T o r q u e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Shims
Axle Shaft Joint Cardan, CV.
Original Bearings 10-20 in. lbs. 1-2 N-m
Lubricant Capacity* . . 50 oz. (1.48L) Replacement Bearings 15.35 in. lbs. 1.5-4 N-m
Axle Model Dana M30F Drive Pinion Gear Depth . . . . . . . . . . . . . . . . . . . Select Shims
Axle Ratio 3.07, 3.55, 4.10 Standard Setting 2.250 in. 57.1 mm
Side Gear Clearance (max.).......... 0.006 in. 0.15 mm

* Command-Trac — add 5 ounces (148 ml) to front axle shift motor
housing opening. Case Runout (max.) . . . . . . . . . . . . . . . . 0.006 in. 0.15 mm
J9302-73
J
XJ FRONT SUSPENSION COMPONENTS YJ FRONT SUSPENSION COMPONENTS

Coil Spring Retainer Screw 21 N m (16 ft. lbs.) Jounce Bumper to Frame S c r e w . . . . 41 N-m (30 ft. lbs.)
Lower Suspension Arm Nuts 115 N-m (85 ft. lbs.) Stabilizer Bar Retainer Bolts 75 N-m (55 ft. lbs.)
Lower Suspension Arm Caster Stabilizer Bar Unk Nut 61 N-m (45 ft. lbs.)
Adjuster Bracket Nuts 19 N-m (14 ft. lbs.) Shock Absorber Lower Bolt 61 N-m (45 ft. lbs.)
Shock Absorber Upper Nut 11 N-m (8 ft. Jbs.) Shock Absorber Upper Nut 13 N-m (9 ft. lbs.)
Shock Absorber Lower Bolt/Nut . . 19 N-m (14 ft. lbs.) Spring U-bolt/Stud Nut 122 N-m (90 ft. lbs.)
Stabilizer Bar Link Nuts 36 N-m (27 ft. lbs.) Spring Front Shackle Bolt 129 N-m (95 ft. lbs.)
Stabilizer Bar Link Axle Spring Rear Pivot Bolt 142 N-m (105 ft. lbs.)
Bracket Bolt 74 N-m (55 ft. lbs.) Track Bar to Axle Nut 100 N m (74 ft. lbs.)
Stabilizer Bar Clamp Bolts 54 N-m (40 ft. lbs.) Track Bar to Frame Bolt 168 N m (125 ft. lbs.)
Track Bar Bracket to Reinforcement Wheel Lug Nut V4 x 20 with
Plate Bolts . 121 N-m (90 ft. lbs.) 60° Cone 109 to 150 N-m
Track Bar Bracket to Stud (80 to 110 ft. lbs.)
Plate Nuts 100 N-m (74 ft. lbs.)
J9302-72
Track Bar Bracket Reinforcement
Plate Side Bolts 42 N-m 31 ft. lbs.)
Track Bar Axle Bracket Bolt 100 N-m 74 ft. lbs.)
Track Bar Ball Stud Retaining Nut . 81 N-m 60 ft. lbs.)
Upper Suspension Arm Rear Nut . 89 N m 66 ft. lbs.)
Upper Suspension Arm Front Nut . 74 N-m 55 ft. lbs.)
Wheel Lug Nut Vi x 20 with
60° Cone 109 to 150 N-m
(80 to 110 ft. lbs.)
MODEL 30 AXLE
J9302-71
DfSCRIPTION TORQUE
Bearing Cap Bolts 77 N-m (57 ft. lbs.)
Differential Cover Bolts 47 N-m (35 ft. lbs.)
Fill Hole Plug 34 N-m (25 ft. lbs.)
Hub BearingtoKnuckle Bolts 102 N-m (75 ft. lbs.)
Hub Bearing to Axle Shaft Nut 237 N-m (175 ft. lbs.)
Lower Ball Stud Nut 108 N-m (80 ft. lbs.)
Upper Ball Stud Nut 101 N-m (75ft.lbs.)
Ring Gear Bolts 61 to 81 N-m (45to60 ft. lbs.)
J9302-70
J R E A R S U S P E N S I O N AND A X L E S 3 - 1
REAR SUSPENSION AND AXLES
CONTENTS
page page
8 1/4 A X L E 33 T O R Q U E SPECIFICATIONS 50
A X L E NOISE/VIBRATION D I A G N O S I S 7 TRAC-LOK DIFFERENTIAL 28
GENERAL INFORMATION 1 XJ SUSPENSION 3
MODEL 3 5 AXLE 11 YJ SUSPENSION 5
SURE-GRIP DIFFERENTIAL 49
GENERAL INFORMATION
SUSPENSION the axle brackets. All mounting points of the stabi
The Jeep® rear suspension is comprised of; lizer bar are isolated by bushings.
• Drive axle The track bar on the YJ is used to minimize rear
• Leaf springs axle side-to-side movement. The track bar is attached
• Dual-action shock absorbers to the frame rail bracket and axle bracket and is iso
• Track bar (YJ vehicles) lated with bushings.
• Stabilizer bar (XJ vehicles)
• Jounce bumpers (used to limit the travel of the AXLES
suspension) The Model 35 axle is standard for XJ and YJ vehi
The rear suspension design uses semi-elliptic multi- cles. The 8 1/4 axle is available in the XJ vehicle
leaf springs and a solid drive axle. The forward end of with a 3.55 gear ratio and without ABS.
the springs are mounted to the frame rail hangers The Model 35 and 8 1/4 axle housings consist of a
through rubber bushings. The bushings isolate road cast iron center section. They also have two steel
noise as the springs move. The rearward end of the axle shaft tubes that are pressed into and welded to
springs are attached to the frame by the use of shack the differential housing.
les. Again the spring and shackles use rubber bushings The removable cover provides for service without
to isolate road noise. The shackles allow the springs to removing the complete axle.
change their length as the vehicle moves over various It is not necessary to remove the axle from the ve
road conditions. The spring and axle travel is limited hicle for routine service. If the differential housing is
through the use of bumpers mounted on frame. damaged, the complete axle can be removed and in
All suspension components that use bushings stalled.
should be tightened with the vehicle at normal For complete drive axle assembly removal and
height. If the springs are not at normal ride position, installation refer to Drive Axle Assembly Re
vehicle ride comfort could be affected. Rubber bush placement in this Group.
ings must never be lubricated.
The springs are attached to the axle pads with IDENTIFICATION
U-bolts and plates. The springs use a center bolt that Model 35 axle has the assembly part number and
holds the spring leafs in position. The bolt is also gear ratio listed on a tag. The tag is attached to the left
used to locate the spring assembly to the axle pad. side of the housing cover (Fig. 1). Build date identifica
Ride control is accomplished through the use of du tion codes on axles are stamped on the axle shaft tube
al-action shock absorbers. The shocks dampen the cover side. The Model 35 axle has a flat housing cover
jounce and rebound as the vehicle travels over vari gasket flange at the outer edge (Fig. 1).
ous road conditions. The top of shock absorbers are The 8 1/4 axle has the build date code and gear ra
bolted to the frame bracket. The bottom of the shocks tio tags attached to the housing cover (Fig. 2). The
are bolted to the axle bracket. housing cover gasket has a rolled gasket flange at
The stabilizer bar on the XJ is used to minimize the outer edge (Fig. 2).
vehicle rear sway during turns. The bar helps to • The Model 35 axle has shaft tubes that are 2.625
maintain a flat attitude to the road surface. The bar inch (66.67 mm) in diameter.
extends across the underside of the chassis and con • The 8 1/4 axle has axle shaft tubes that are 3.0-
nects to the frame rails. The links are connected to inch (76.2 mm) in diameter.
3 - 2 REAR SUSPENSION AND AXLES
DIFFERENTIAL • The ring gear (bolted to the differential case) ro

J
COVER tates the case
PUSH-IN
• The differential pinion gears (mounted on the pin
FILL P L U G ion mate shaft in the case) rotate the side gears
AXLE M O D E L
• 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. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 3).
IN S T R A I G H T A H E A D DRIVING
EACH W H E E L ROTATES AT 100%
O F CASE S P E E D
LIMITED SLIP
IDENTIFICATION TAG
TAG
J9203-10
Fig. 1 Model 35 Differential Cover
DIFFERENTIAL IDENTIFICATION
COVER TAG
P I N I O N G E A R S ROTATE
W I T H CASE J9303-13
Fig. 3 Differential Operation—Straight-Ahead Driving

When turning corners, the outside wheel must travel
a greater distance than the inside wheel in order to
complete a turn. This difference must be compensated
for in order to prevent the wheels from scuffing and
skidding through the turn. To accomplish this, the dif
ferential becomes effective allowing the axle shafts to
turn at unequal speeds (Fig. 4). In this instance, the in
put torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to ro
tate at a faster speed.
PUSH-IN AXLE <t
FILL P L U G J9203-11 OUTER WHEEL 100% D I F F E R E N T I A L INNER WHEEL

/
Fig. 2 Differential Cover—8 1/4 110% CASE S P E E D CASE S P E E D 9 0 % CASE S P E E D
STANDARD DIFFERENTIAL OPERATION

The differential gear system divides the torque be
tween the axle shafts. It allows the axle shafts to ro
tate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
P I N I O N G E A R S ROTATE
In operation, power flow occurs as follows: ON PINION SHAFT J9303-14
• The pinion gear rotates the ring gear
Fig. 4 Differential Operation—On Turns
REAR SUSPENSION AND AXLES 3 -3
J
XJ SUSPENSION
INDEX
page page
Leaf Spring 4 Shock Absorber 3
Leaf Spring Eye Bushing Replacement ......... 4 Spring and Shock Diagnosis 3
Service Information 3 Stabilizer Bar—XJ Vehicles 4
SERVICE INFORMATION an upright position and force the piston into and out
of the cylinder four or five times. The action through
CAUTION: All suspension components that use rub out each stroke should be smooth and even.
ber bushings should be tightened with the vehicle
at the normal height. It i s important to have the SHOCK ABSORBER
springs supporting the weight of the vehicle when
the fasteners are torqued. If the springs are not at REMOVAL
their normal ride position, vehicle ride comfort (1) Remove the shock absorber upper fasteners
could be affected along with premature rubber from the frame bracket (Fig. 1).
bushing wear. Rubber bushings must never be lu (2) Remove the lower attaching nut and washer
bricated. from the bracket stud. Remove the shock absorber.
INSTALLATION
SPRING AND SHOCK DIAGNOSIS (1) Install the shock absorber lower eye on the
A squeak noise from the shock absorber can be pro spring bracket stud. Install the shock absorber and
duced if movement between the rubber bushings and upper attaching fasteners on the frame bracket (Fig.
the metal occurs. This noise can usually be stopped 1).
by tightening the attaching nuts. If the squeak noise (2) Tighten the nuts to 60 N*m (44 ft. lbs.) torque.
persists, inspect for damaged and worn bushings, and (3) Tighten the screws to 20 N*m (15 ft. lbs.)
attaching components. Repair as necessary if any of torque.
these conditions exist.
The shock absorbers are not refillable or adjust
able. If a malfunction occurs, the shock absorber
SCREW
VIEW IN DIRECTION
OF ARROW Z
SHACKLE
OF ARROW Y
SHOCK
BUSHING ABSORBER
J9217-3
U-BOLTS
Fig. 1 Spring & Shock Absorber—XJ Vehicles

J
LEAF S P R I N G NUT PIPE
(RECEIVER)
REMOVAL
(1) Raise vehicle at frame.
(2) Use a hydraulic jack to relieve axle weight. SPRING
EYE
(3) As applicable, disconnect the shock absorber
from the axle bracket or the spring bracket (Fig. 1).
(4) Remove the wheel and tire.
(5) Disconnect the stabilizer bar link from the
spring bracket stud.
(6) Remove nuts, U-bolts and spring bracket from NUT
axle (Fig. 1).
(7) Reinove nut and bolt attaching spring front eye
to shackle (Fig. 1).
(8) Remove nut and bolt from spring rear eye (Fig. 1).
(9) Remove spring from vehicle.
SOCKET
INSTALLATION WRENCH
(DRIVER)
(1) Position the spring front eye in the bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time. FLAT THREADED
WASHER ROD J8917-20
(2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut (Fig. 1). Do
not tighten at this time. Fig. 2 Spring Eye Bushing Removal
(3) Position the axle. Install the spring bracket, frame rails. Remove the stabilizer bar and links.
U-bolts and nuts (Fig. 1). Tighten the nuts to 70 N T H UNK BUSHING.
(4) Connect the stabilizer bar link to the spring
bracket.
(5) Connect the shock absorber to the axle bracket
or spring bracket.
(6) Remove the hydraulic jack.
(7) Remove the support stands and lower the vehicle.
(8) Tighten the spring front and rear eye attaching
bolts to 88 N-m (65 ft. lbs.) torque.
LEAF SPRING EYE BUSHING REPLACEMENT

(1) Assemble tools shown (Fig. 2). Tighten the nut
located at the socket wrench end of the threaded rod
until the bushing is forced out.
(2) Assemble and align the bushing installation tools.
(3) Align the bushing with the spring eye. Tighten
the nut located at the socket wrench end of the SPRING
threaded rod. Tighten until the bushing is forced into BRACKET
the spring eye.
The bushing must be centered in the spring J9217-6
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the Fig. 3 Stabilizer Bar—XJ Vehicles
spring eye.
INSTALLATION
STABILIZER B A R - X J VEHICLES (1) Position the stabilizer bar links at the spring
brackets (Fig. 3). Install the attaching bolts and nuts
REMOVAL and tighten to 95 N*m (70 ft. lbs.) torque.
(1) Raise and support the vehicle. (2) Attach the stabilizer bar to the frame rail
(2) Disconnect stabilizer bar links from spring brackets with the bolts. Tighten to 75 N*m (50 ft.
brackets (Fig. 3). lbs.).
(3) Disconnect the stabilizer bar brackets from the (3) Remove the supports and lower the vehicle.
J REAR SUSPENSION AND AXLES 3 -5
YJ SUSPENSION
INDEX
page page
Leaf Spring 5 Shock Absorber 5
Leaf Spring Eye Bushing Replacement ......... 5 Spring and Shock Diagnosis 5
Service Information 5 Track Bar 6
SERVICE INFORMATION (4) Remove the nuts, the U-bolts and spring
bracket from the axle (Fig. 1).
CAUTION: All suspension components that use rubber
(5) Remove the nut and bolt that attaches the
bushings should be tightened with the vehicle at the
spring rear eye to the shackle (Fig. 1).
normal height. It is important to have the springs sup
(6) Remove the nut and bolt from the spring front
porting the weight of the vehicle when the fasteners
eye (Fig. 1).
are torqued. If the springs are not at their normal ride
(7) Remove the spring from the vehicle.
position, vehicle ride comfort could be affected. Rub
ber bushings must never be lubricated. INSTALLATION
(1) Position the spring front eye in the bracket.
SPRING AND SHOCK DIAGNOSIS Loosely install the attaching bolt and nut (Fig. 1). Do
A squeak noise from the shock absorber can be pro not tighten at this time.
duced if movement between the rubber bushings and the (2) Position the rear eye in the shackle bracket.
metal occurs. This noise can usually be stopped by tight Loosely install the attaching bolt and nut (Fig. 1). Do
ening the nuts. If the squeak noise persists, inspect for not tighten at this time.
damaged and worn bushings, and attaching components. (3) Align the rear spring center bolt with the locat
Repair as necessary if any of these conditions exist. ing hole in the rear axle spring pad.
The shock absorbers are not refillable or adjust (4) Lower the rear axle until it is completely sup
able. If a malfunction occurs, the shock absorber ported by the spring.
must be replaced. To test a shock absorber, hold it in Ensure that the spring center bolt is seated in
an upright position and force the piston into and out the axle spring pad locating hole. Realign the
of the cylinder four or five times. The action through center bolt with the locating hole, if necessary.
out each stroke should be smooth and even. (5) Position the axle. Install the spring bracket,
U-bolts and nuts (Fig. 1). Tighten the U-bolt nuts to
SHOCK ABSORBER 122 N«m (90 ft. lbs.) torque.
REMOVAL (6) Remove the hydraulic jack.
(1) Remove the upper attaching nut and washer (7) Remove the support stands and lower the vehi
from the frame bracket stud (Fig. 1). cle.
(2) Remove the lower attaching nut, washers and (8) Tighten the spring eye-to-shackle plate bolt to
bolt from the axle bracket. Remove the shock ab 129 N*m (95 ft. lbs.) torque.
sorber (Fig. 1). (9) Tighten the spring eye-to-frame bracket bolt to
142 N-m (105 ft. lbs.) torque.
INSTALLATION
(1) Position the shock upper eye on the frame LEAF SPRING EYE BUSHING REPLACEMENT
bracket stud. Install the washer and nut (Fig. 1). (1) Assemble tools shown (Fig. 2). Tighten the nut
(2) Position the shock lower eye in the axle shaft located at the socket wrench end of the threaded rod
tube bracket. Install the lower attaching bolt, wash until the bushing is forced out.
ers and nut (Fig. 1). (2) Assemble and align the bushing installation
(3) Tighten the upper and lower attaching bolt and tools.
nuts to 60 N*m (44 ft. lbs.) torque. (3) Align the bushing with the spring eye and
tighten the nut located at the socket wrench end of
LEAF SPRING the threaded rod. Tighten until the bushing is forced
into the spring eye.
REMOVAL The bushing must be centered in the spring
(1) Raise the vehicle at the frame. eye. The ends of the bushing must be flush or
(2) Use a hydraulic jack to relieve the axle weight. slightly recessed within the end surfaces of the
(3) Remove the wheel and tire. spring eye.
3 - e REAR SUSPENSION AND AXLES J
Fig. 1 Spring & Shock Absorber— YJ Vehicles

TRACK BAR (2) Remove the fasteners that attach the track bar
to the frame bracket and axle bracket (Fig. 3).
REMOVAL (3) Remove the track bar from the vehicle.
(1) Raise the vehicle. Position a hydraulic jack un
der the axle and raise the axle to relieve the springs INSTALLATION
of axle weight. (1) Position the ends of the track bar in the frame
and axle brackets (Fig. 3).
(2) Install and tighten the track bar attaching nuts
to 168 N*m (125 ft. lbs.) torque.
NUT PIPE BOLT
WASHER ROD J8917-20 BRACKET MOUNT J9217-7
Fig. 2 Spring Eye Bushing Removal Fig. 3 Track Bar— YJ Vehicles

J REAR SUSPENSION AND AXLES 3-7
AXLE NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Driveline Snap 8 Low Speed Knock 8
Gear and Bearing Noise 7 Rear Axle Alignment 8
General Information 7 Vibration 8
Limited Slip Differential 8
GENERAL INFORMATION GEAR AND BEARING NOISE

Axle bearing problem conditions are usually caused
by: GEAR NOISE
• Insufficient or incorrect lubricant Axle gear noise can be caused by insufficient lubri
• Foreign matter/water contamination cant. Incorrect backlash, tooth contact, or worn/dam
aged gears can cause noise.
• Incorrect bearing preload torque adjustment
When serviced, the bearings must be cleaned thor Gear noise usually happens at a specific speed
range. The range is 30 to 40 mph, or above 50 mph.
oughly. They should be dried with lint-free shop tow
The noise can also occur during a specific type of
els. Never dry bearings with compressed air.
driving condition. These conditions are acceleration,
This will overheat them and brinell the bearing deceleration, coast, or constant load.
surfaces. This will result in noisy operation after When road testing, accelerate the vehicle to the
repair. speed range where the noise is the greatest. Shift
Axle gear problem conditions are usually the result out-of-gear and coast through the peak-noise range.
of: If the noise stops or changes greatly, check for insuf
• Insufficient lubrication ficient lubricant. Incorrect ring gear backlash, or
• Incorrect or contaminated lubricant gear damage can cause noise changes.
• Overloading (excessive engine torque) Differential side and pinion gears can be checked
• Incorrect clearance or backlash adjustment by turning the vehicle. They usually do not cause
Insufficient lubrication is usually the result of a noise in straight-ahead driving. These gears are
housing cover leak. It can also be from worn axle loaded during vehicle turns. If noise does occur dur
shaft or pinion gear seals. Check for cracks or porous ing vehicle turns, the side or pinion gears could be
areas in the housing or tubes. worn or damaged. A worn pinion gear mate shaft can
Using the wrong lubricant will cause overheating also cause a snapping or a knocking noise.
and gear failure. Gear tooth cracking and bearing
spalling are indicators of this. BEARING NOISE
Axle component breakage is most often the result The axle shaft, differential and pinion gear bear
of: ings can all produce noise when worn or damaged.
• Severe overloading Bearing noise can be either a whining, or a growling
• Insufficient lubricant sound.
Pinion gear bearings have a constant-pitch noise.
• Incorrect lubricant
This noise changes only with vehicle speed. Pinion
• Improperly tightened components
bearing noise will be higher because it rotates at a
Overloading occurs when towing heavier than rec faster rate. Drive the vehicle and load the differen
ommended loads. Component breakage can occur tial. If bearing noise occurs the pinion rear bearing is
when the wheels are spun excessively. Incorrect lu the source of the noise. If the bearing noise is heard
bricant quantity contributes to breakage. Loose dif during a coast, front bearing is the source.
ferential components can also cause breakage. Worn, damaged differential bearings usually pro
Incorrect bearing preload or gear backlash will not duce a low pitch noise. Differential bearing noise is
result in component breakage. Mis-adjustment will similar to pinion bearing. The pitch of differential
produce enough noise to cause service repair before a bearing noise is also constant and varies only with
failure occurs. If a mis-adjustment condition is not vehicle speed.
corrected, component failure can result. Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
3 - 8 REAR SUSPENSION AND AXLES J
level. Where axle bearing damage is slight, the noise (2) Attach a one-inch long piece of masking tape at
is usually not noticeable at speeds above 30 mph. the center of each tire tread for use as reference marks.
(3) Rotate the rear wheels until both reference
LOW SPEED KNOCK marks face the front of the vehicle. Measure the dis
Low speed knock is generally caused by a worn tance between the outside edges of the two pieces of
U-joint or by worn side-gear thrust washers. A worn tape. Record this measurement as the front of tire
pinion gear shaft bore will also cause low speed (FTR) measurement.
knock. (4) Rotate the rear wheels until both reference
marks face the rear of the vehicle. Measure the dis
VIBRATION tance between the outside edges of the two pieces of
Vibration at the rear of the vehicle is usually tape. Record this measurement as the rear of tire
caused by a: (RTR) measurement.
• Damaged drive shaft (5) Subtract the (RTR) measurement from the
• Missing drive shaft balance weight (FTR) measurement to obtain the amount of wheel
• Worn, out-of-balance wheels toe. The acceptable rear wheel toe-in position is 1/16
• Loose wheel lug nuts inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out.
• Worn U-joint (6) Rotate the rear wheels until the reference
• Loose spring U-bolts marks are facing downward. Measure the distance
• Loose/broken springs between the outside edges of the two pieces of tape.
• Damaged axle shaft bearings Record this measurement as the bottom of tire (BTR)
• Loose pinion gear nut measurement.
• Excessive pinion yoke run out
(7) Average the (FTR) and the (RTR) distance
• Bent axle shaft
measurements. Subtract the (BTR) measurement
Check for loose or damaged front-end components
from this average distance to obtain the camber. The
or engine/transmission mounts. These components
acceptable amount of camber is 1/16 inch to 3/32 inch
can contribute to what appears to be a rear-end vi
(1.6 to 2.4 mm).
bration. Do not overlook engine accessories, brackets
and drive belts. (FTR + RTR) DIVIDED BY 2 (TWO) MINUS
All driveline components should be examined be BTR EQUALS CAMBER
fore starting any repair. If the (BTR) distance measurement is less than
Refer to Group 22, Wheels and Tires for additional the average FTR and R T R distance measure
information. ment, the camber will be positive ( + ) . If the
(BTR) distance measurement is greater than the
DRIVELINE SNAP average FTR and RTR distance, the camber will
A snap or clunk noise when the vehicle is shifted be negative ( - ) .
into gear (or the clutch engaged), can be caused by: If the toe position or camber is not acceptable, a
• High engine idle speed bent or deformed rear axle shaft is most likely the
• Loose engine/transmission/transfer case mounts cause.
• Worn U-joints
• Loose spring mounts LIMITED SLIP DIFFERENTIAL
• Loose pinion gear nut and yoke Under normal traction conditions, engine torque is
• Excessive ring gear backlash divided evenly. With low-traction surfaces, engine
• Excessive side gearase clearance torque is transferred to the wheel with the most tire
The source of a snap or a clunk noise can be deter traction. When diagnosing a limited-slip differential
mined with the assistance of a helper. Raise the ve problem condition, the wheel with the least traction
hicle on a hoist with the wheels free to rotate. can continue spinning.
Instruct the helper to shift the transmission into The most common problem is a chatter noise when
gear. Listen for the noise, a mechanics stethoscope is turning corners. Check for incorrect or contaminated
helpful in isolating the source of a noise. lubricant. Replace the gear lubricant if necessary.
• With Trac-Lok differentials add a container of MO
REAR AXLE ALIGNMENT PAR® Trac-Lok Lubricant.
• With Sure-Grip differentials add a container of
MEASUREMENT MOPAR® Hypoid Gear Additive.
The following procedure can be used to determine This will correct the condition in most instances. If
if abnormal rear tire tread wear is the result of a the chatter persists, clutch damage could have occurred.
bent or deformed rear axle shaft. After changing the lubricant, drive the vehicle and
(1) Raise both rear wheels off the surface with a make 10 to 12 slow, figure-eight turns. This maneu
frame contact hoist. ver will pump lubricant through the clutches.
REAR SUSPENSION AND AXLES 3
SERVICE DIAGNOSIS

W H E E L NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
A X L E S H A F T NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearings. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct as
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(f) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE S H A F T BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
D I F F E R E N T I A L CASE (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
damage. Avoid erratic use of clutch.
DIFFERENTIAL GEARS (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
L O S S OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
3-10 REAR SUSPENSION AND AXLES
SERVICE DIAGNOSIS (CONT'D)

(b) Worn axle shaft seals. (b) Replace worn seals.
(c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal,
(e) Scored and worn yoke. (t) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
A X L E OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash. (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR T E E T H B R O K E (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
A X L E NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
REAR SUSPENSION AND AXLES 3-11
MODEL 3 5 AXLE
INDEX
page page
Axle Shaft 14 Drive Axle Assembly Replacement—XJ Vehicles . 11
Axle Shaft Seal and Bearing . 15 Drive Axle Assembly Replacement—YJ Vehicles . 12
Axle Specifications 27 Final Assembly 25
Backlash and Contact Pattern Analysis . . . . . . . . 24 General Information 11
Cleaning/Inspection 18 Lubricant Change 13
Differential Assembly 19 Lubricant Specifications 11
Differential Disassembly . 16 Pinion Gear Assembly/Installation 20
Differential Installation 23 Pinion Gear Depth Information . 19
Differential Removal 16 Pinion Removal/Disassembly 17
Differential Shim Pack Measurement and Pinion Shaft Seal Replacement 13
Adjustment 22 Ring Gear Installation 23
GENERAL INFORMATION For complete drive axle assembly removal and

The housing for Model 35 rear axles consists of an installation refer to Drive Axle Assembly Re
iron center casting (differential housing) with axle placement in this Group.
shaft tubes extending from either side. The tubes are
pressed into and welded to the differential housing to
Multi-purpose, hypoid gear lubricant should be
form a one-piece axle housing. used for Model 35 axle. The lubricant should have
The integral type housing, hypoid gear design has MIL-L-2105C and API GL 5 quality specifications.
the centerline of the pinion set below the centerline MOPAR® Hypoid Gear Lubricant conforms to both of
of the ring gear. these specifications.
The axle has a fitting for a vent hose used to re • The factory installed lubricant for the standard
lieve internal pressure caused by lubricant vaporiza Model 35 axle is SAE 90W gear lubricant.
tion and internal expansion. • Lubricant for Model 35 axle with Trailer Tow and
The axles are equipped with semi-floating axle Trac-lok is SAE 75W-140 SYNTHETIC gear lubri
shafts, meaning that loads are supported by the axle cant with friction modifier.
shaft and bearings. The axle shafts are retained by • The factory installed lubricant quantity is 40 ±1
C-clips in the differential side gears. fluid oz.
The cover provides a means for servicing the differ Refer to Group 0, Lubrication and Maintenance for
ential without removing the axle. additional information.
Axles that are equipped with ABS brake sensors. CAUTION: If the axle i s submerged in water, the lu
The sensors are attached to the brake backing plate bricant must be replaced immediately to avoid the
assemblies and tone rings are pressed on the axle possibility of premature axle failure.
shaft. Use care when removing axle shafts as NOT to
damage the tone wheel or the sensor.
The Model 35 axle has the assembly part number DRIVE AXLE ASSEMBLY REPLACEMENT-XJ
and gear ratio listed on a tag. The tag is attached to VEHICLES
the housing cover. Build date identification codes are
stamped on the axle shaft tube cover side. REMOVAL
The differential case is a one-piece design. The dif (1) Raise the vehicle and position support stands
ferential pinion mate shaft is retained with a under the frame rails slightly in front the springs.
threaded roll pin. Differential bearing preload and (2) Remove the rear wheels.
ring gear backlash is adjusted by the use of spacer (3) Mark the drive shaft yoke and axle pinion yoke
shims. Pinion bearing preload is set and maintained for alignment reference. Disconnect the drive shaft
by the use of a collapsible spacer. from the axle.
It is not necessary to remove the complete axle (4) Disconnect the axle vent hose.
from the vehicle for routine or differential service. If (5) Disconnect the parking brake cables at the
the differential housing or axle shaft tubes are dam equalizer or backing plate.
aged, the complete axle can be removed and in (6) Disconnect the shock absorbers from the axle
stalled. brackets.
3 - 12 R E A R S U S P E N S I O N AND A X L E S
J
(7) Disconnect the brake hose at the axle junction (4) Disconnect the axle vent hose.
block. Do not disconnect the wheel cylinder tub (5) Disconnect the parking brake cables at the
ing fittings, equalizer or backing plate.
(8) If equipped, disconnect ABS wiring connections (6) Disconnect the shock absorbers from the plate
at the axle. brackets.
(9) Support the axle with a hydraulic jack under (7) Disconnect the brake hose at the axle junction
the differential. block. Do not disconnect the wheel cylinder tub
(10) Remove the spring U-bolts from the plate ing fittings.
brackets. (8) Disconnect the track bar at the axle bracket.
(9) Support the axle with a hydraulic jack under
(11) Lower the jack enough to remove the axle. the differential. Raise the axle just enough to relieve
INSTALLATION the axle weight from the springs.
(10) Remove the spring U-bolts from the plate
CAUTION: All suspension components that use rub brackets.
ber bushings should be tightened with the vehicle
(11) Loosen BUT DO NOT REMOVE the bolts that
at the normal height. It i s important to have the
attach the spring front pivot at the frame rail brack
ets. This will allow the springs to pivot without bind
the fasteners are torqued. If the springs are not at
ing on the bushings.
their normal ride position, vehicle ride comfort
(12) Disconnect shackle from the springs and lower
could be affected along with premature rubber
the springs to the surface.
bushing wear. Rubber bushings must never be lu
(13) Lower the jack enough to remove the axle.
bricated.
INSTALLATION
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle. CAUTION: All suspension components that use rub
(2) Raise the axle and align the spring center bolts ber bushings should be tightened with the vehicle
with the locating holes in the axle pads and plate at the normal height. It i s important to have the
brackets.
(3) Install the spring U-bolts through the plate
the fasteners are torqued. If the springs are not at
brackets and tighten to 70 N*m (52 ft. lbs.) torque.
their normal ride position, vehicle ride comfort
(4) Install ABS wiring connections (if equipped) at
could be affected along with premature rubber
the axle.
bushing wear. Rubber bushings must never be l u
(5) Connect the brake hose at the axle junction
block. bricated.
(6) Install the shock absorbers to the axle brackets
(1) Support the axle on a hydraulic jack under the
and tighten to 60 N*m (44 ft. lbs.) torque.
(7) Connect the parking brake cables at the equal differential. Position the axle under the vehicle.
izer or backing plate. (2) Raise the springs and install the spring shackle
(8) Connect the vent hose to the tube fitting. bolts. Do not tighten at this time.
(9) Align the reference marks and connect the (3) Lower the axle and align the spring center
drive shaft to the axle yoke. Tighten the U-joint bolts with the locating holes in the axle pads and
#
clamp bolts to 19 N m (14 ft. lbs.) torque. plate brackets.
(10) Check differential lubricant and add if neces (4) Install the spring U-bolts through the plate
sary. brackets and tighten to 122 N*m (90 ft. lbs.) torque.
(11) Install the wheel and tire. (5) Connect the track bar to the axle bracket and
(12) Bleed the brakes. install the bolt. Do not tighten at this time.
(13) Remove the supports and lower the vehicle. It is important that the springs support the
DRIVE AXLE ASSEMBLY REPLACEMENT—YJ nected. If the springs are not at their usual po
VEHICLES sition, vehicle ride comfort could be affected.
(6) Connect the brake hose at the axle junction
REMOVAL
block.
(1) Raise the vehicle and position support stands
under the frame rails slightly in front the springs. (7) Install the shock absorbers to the axle brackets
(2) Remove the rear wheels. and tighten to 61 N»m (45 ft. lbs.) torque.
(3) Mark the drive shaft yoke and axle pinion yoke (8) Connect the parking brake cables at the equal
for alignment reference. Disconnect the drive shaft izer or backing plate.
from the axle. (9) Connect the vent hose to the tube fitting.
J R E A R S U S P E N S I O N AND A X L E S 3 -13
(10) Align the reference marks and connect the (7) Install the cover and any identification tag.
drive shaft to the axle yoke. Tighten the U-joint Tighten the cover bolts to 47 N»m (35 ft. lbs.) torque.
clamp bolts to 19 N*m (14 ft. lbs.) torque. (8) Refill the differential with MOPAR® Hypoid
(11) Check differential lubricant and add if neces Gear Lubricant within 13 mm (1/2 in.) below the fill
sary. plug hole.
(12) Install the wheel and tire. Trac-Lok Differentials; A container of Trac-Lok Lu
(13) Bleed the brakes. bricant (friction modifier) should be added after re
(14) Remove the supports and lower the vehicle. pair service or a lubricant change.
(15) Tighten the spring front pivot bolt/nut to 142 (9) Install the fill hole plug and lower the vehicle.
N*m (105 ft. lbs.) torque. Tighten the spring shackle LIMITED SLIP DIFFERENTIAL vehicles should
bolt/nut to 135 N«m (100 ft. lbs.) torque. be road tested by making 10 to 12 slow figure-eight
(16) Tighten the track bar bolt at the axle bracket turns. This maneuver will pump the lubricant
to 142 N-m (105 ft. lbs.) torque. through the clutch discs to eliminate a possible chat
ter noise complaint.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle PINION SHAFT SEAL REPLACEMENT
has been recently driven.
(1) Raise and support the vehicle, REMOVAL
(2) Remove the lubricant fill hole plug from the (1) Raise and support the vehicle.
differential housing cover. (2) Mark the drive shaft yoke and pinion yoke for
(3) Remove the differential housing cover and installation alignment reference.
drain the lubricant from the housing. (3) Remove the drive shaft from the yoke.
(4) Clean the housing cavity with a flushing oil, (4) Rotate the pinion gear three or four times.
light engine oil or lint free cloth. Do not use water, (5) Measure the amount of torque (in Newton-
steam, kerosene or gasoline for cleaning. meters or inch-pounds) necessary to rotate the pinion
(5) Remove the sealant from the housing and cover gear with a torque wrench. Note the torque for in
surfaces. stallation reference. It must be known to properly
(6) Apply a bead of MOPAR® Silicone Rubber Seal adjust the pinion gear bearing preload torque
ant to the housing cover (Fig. 1). Allow the sealant after seal installation.
to cure for a few minutes. (6) Remove the pinion yoke nut and washer. Use
SEALING CONTOUR OF BEAD pinion yoke (Fig. 2).
(7) Mark the positions of the yoke and pinion gear
G452 J9102-31
Fig. 1 Typical Housing Cower With Sealant (8) Use Remover W-251 to remove the pinion gear
seal (Fig. 3).
Install the housing cover within 5 minutes af
ter applying the sealant. If not installed the seal
ant must be removed and another bead applied.
3-14 REAR SUSPENSION AND AXLES J
atin tiivn iv-iitjiiictii i i n y i . L^W I I V I VAI#TCVI tiucac
ing preload torque. T h e collapsible preload spacer

on the shaft will have to be replaced. T h e bearing
preload torque will be re-adjusted afterward.
(4) Install a socket and inch-pound torque wrench

on the pinion nut.
(5) Rotate the shaft with the torque wrench and
note the torque.
The required preload torque is equal to the
amount recorded during removal plus an addi
tional 0.56 N*m (5 in. lbs.).
(6) Use Flange Wrench C-3281 to retain the yoke
and shaft (Fig. 5). Tighten the shaft nut in very
small increments.
W-251
(J25180) DIFFERENTIAL
J9202-33
Fig. 3 Seal Removal

INSTALLATION
lip of pinion seal. Install seal with Installer W-147-E
and Handle C-4171 (Fig. 4).

(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.
(9) Add API grade GL 5 hypoid gear lubricant to
the differential housing, if necessary.
Fig. 4 Pinion Seal Installation AXLE SHAFT

(2) Align the installation reference marks and in REMOVAL
stall yoke on the pinion gear with Installer W-162-D. (1) Raise and support the vehicle.
(3) Install a new nut on the pinion gear. Tighten (2) Remove the wheel and tire.
the nut only enough to remove the shaft end (3) Remove the brake drum.
play. (4) Clean all the foreign material from housing
cover area.
CAUTION; Exercise care during the bearing preload
torque adjustment. Do not over-tighten, or loosen
REAR SUSPENSION AND AXLES 3 - 15
J
(5) Loosen the housing cover bolts. Drain the lubri bearing, and engage it with the side gear splines.
cant from the housing and the axle shaft tubes. Re Use care to prevent the shaft splines from dam
move the housing cover. aging the axle shaft seal lip.
(6) Rotate the differential case so that the pinion (2) Insert the C-clip lock in the end of the axle
mate gear shaft lock screw is accessible. Remove the shaft. Push the axle shaft outward to seat the C-clip
lock screw and the pinion mate gear shaft from the lock in the side gear.
case (Fig. 6). (3) Insert the mate shaft into the case and through
the thrust washers and pinion gears. Align the hole
in shaft with the hole in the differential case and in
stall the lock screw with Loctite® on the threads.
Tighten the screw to 19 N*m (14 ft. lbs.) torque.
(4) Install the cover and add fluid. Refer to the
Drain and Refill in this section.
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.
The seal and bearing can be removed at the same
time with the bearing removal tool.
Fig. 6 Mate Shaft Lock Screw (4) Remove the axle shaft bearing from the tube
(7) Force the axle shaft in toward the center of the (Fig. 8) with Bearing Removal Tool Set 6310 (T.Ar
vehicle. Remove the axle shaft C-clip lock from the 960-02).
axle shaft (Fig. 7). AXLE S H A F T
TUBE
Fig. 7 Axle Shaft C-Clip Lock

(8) Remove the axle shaft. Use care to prevent
damage to the axle shaft bearing, which will remain
in the axle shaft tube.
FOOT ADAPTER J9003-51
(9) Inspect the roller bearing contact surface on
the axle shaft for signs of brinelling, spalling and Fig. 8 Axle Shaft Bearing Removal Tool
pitting.
(5) Inspect the axle shaft tube bore for roughness
(10) If any of these conditions exist, the axle shaft
and burrs. Remove as necessary.
and bearing must be replaced.
CAUTION: Inspect the housing bore for burrs. R e
INSTALLATION
move them if they exist.
(1) Lubricate the bearing bore and seal lip with
gear lubricant. Insert the axle shaft through the seal,
3-16 REAR SUSPENSION AND AXLES J
INSTALLATION (3) Position Spreader W-129-A with the tool dowel
Do not install the original axle shaft seal. Al pins seated in the locating holes (Fig. 11). Install the
ways install a new seal. holddown clamps and tighten the tool turnbuckle fin
(1) Wipe the bore in the axle shaft tube clean. ger-tight.
(2) Install axle shaft bearing with Installer 6436
and Handle C-4171. Ensure part number on the
bearing must go against the Installer.
(3) Install the new axle shaft seal (Fig. 9) with In
staller 6437 and Handle C-4171.
SPECIAL
TOOL 6437

C-4171 TUBE J9103-8 stud. Load the indicator plunger against the opposite
side of the housing (Fig. 11) and zero the indicator.
Fig. 9 Axle Shaft Seal Installation
CAUTION: Do not spread over 0.38 mm (0.015 in). If
(4) Install the Axle Shaft. Refer to the installation
the housing i s over-separated, it could be distorted
procedure.
or damaged.
DIFFERENTIAL REMOVAL (5) Separate the housing enough to remove the
To service the differential the axle shafts must be
case from the housing. Measure the distance with the
removed. Refer to the removal procedures in this
dial indicator (Fig. 11).
Group.
(1) Note the installation reference letters stamped
(7) Pry the differential case loose from the hous
on the bearing caps and housing machined sealing ing. To prevent damage, pivot on housing with the
surface (Fig. 10). end of the pry bar against spreader (Fig. 12).
(8) Remove the case from housing. Mark or tag
bearing cups and outboard shim/spacer (selected
thickness) indicating which side they were removed.
Remove spreader from housing.
DIFFERENTIAL DISASSEMBLY
(1) Remove the bearings from the differential case
with Press C-293-PA, Plug SP3289, Adapter
C-293-18 (Fig. 13).
bearing cage.
(2) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
bolts. Tap the ring gear with a rawhide mallet and
remove (Fig. 14).
(3) Rotate the differential side gears and remove
Fig. 10 Bearing Cap Identification the pinion mate gears and thrust washers (Fig. 15).
(4) Remove the differential side gears and thrust
(2) Remove the differential bearing caps.
washers.
(5) Remove the case from the vise.
DIFFERENTIAL PRY BAR CASE RING GEAR
RAWHIDE
HAMMER
J9202-76
Fig. 14 Ring Gear Removal

THRUST
WASHER
J9302-18
Fig. 12 Differential Removal

ADAPTERS
SPECIAL
TOOL PINION
G293-PA MATE GEAR SIDE G E A R J9203-61
Fig. 15 Pinion Mate Gear Removal

(2) Remove the pinion gear seal with a slide ham
mer or pry out with bar.
(3) Remove the pinion gear from housing (Fig. 17).
Catch the pinion with your hand to prevent it from
falling and being damaged.
(4) Remove the collapsible preload spacer (Fig. 18).
(5) Remove oil slinger, front bearing.
PLUG
(6) Remove the front pinion bearing cup with Re
mover D-147 and Handle C-4171 (Fig. 19).
J9202-42 (7) Remove the rear bearing cup from housing
(Fig. 20). Use Remover D-148 and Handle C-4171.
Fig. 13 Differential Bearing Removal (8) Remove the inner bearing from the pinion with
PINION REMOVAL/DISASSEMBLY Puller C-293-PA and Adapter C-293-39 (Fig. 21).
(1) Remove the pinion yoke nut and washer. Use Place adapter rings so they do not damage the
bearing cage.
(9) Remove the depth shims from the pinion gear
pinion yoke (Fig. 16).
shaft. Record the thickness of the depth shims.
J
Fig. 18 Collapsible Spacer
Fig. 17 Remove Pinion Gear

CLEANING/INSPECTION
Wash differential components with cleaning sol Fig. 19 Front Bearing Cup Removal
vent and dry with compressed air. Do not steam • Wear and damage to pinion gear mate shaft, pin
clean the differential components. ion gears, side gears and thrust washers. Replace as
Wash bearings with solvent and towel dry, do not a matched set only.
dry with compressed air. Cup and bearing must be • Ring and pinion gear for worn and chipped teeth
replaced as a matched sets only.
• Ring gear for damaged bolt threads. Replaced as a
Clean the axle shaft tubes with a stiff wire or a
matched set only.
clean cloth.
• Pinion yoke for cracks, worn splines, pitted areas,
Inspect for;
• Smooth appearance with no broken/dented surfaces and a rough/corroded seal contact surface. Repair or
on the bearing rollers or the roller contact surfaces replace as necessary.
• Bearing cups must not be distorted or cracked • Preload shims for damage and distortion. Install
• Machined surfaces should be smooth and without new shims if necessary.
any raised edges
• Raised metal on shoulders of cup bores should be
removed with a hand stone
REAR SUSPENSION AND AXLES 3-19
J PINION GEAR DEPTH INFORMATION
Gears are supplied as matched sets only. The iden
tifying numbers for the ring and pinion gear are
DRIVER
etched into the face of each gear (Fig. 22). A plus ( + )
HANDLE 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 2.095 inches
(53.21 mm) for Model 35 axles. The standard depth
provides the best teeth contact pattern.
DRIVE P I N I O N
PRODUCTION GEAR DEPTH
NUMBERS VARIANCE
J9302-23
Fig. 20 Rear Bearing Cup Removal

SPECIAL
TOOL
C-293-PA
G E A R MATCHING N U M B E R
(SAME A S R I N G G E A R NUMBER) J9003-100
Fig. 22 Pinion Gear ID Numbers

THE BUTTON END ON THE PINION GEAR
HEAD IS NO LONGER A MACHINED-TO-SPECI-
FICATIONS SURFACE. DO NOT USE THIS SUR
DRIVE FACE FOR PINION DEPTH SET-UP OR
PINION CHECKING (Fig. 23).
GEAR
SHAFT PINION
N O T A M A C H I N E D SURFACE BUTTON
END
ADAPTERS
J9202-41
Fig. 21 Inner Bearing Removal

DIFFERENTIAL ASSEMBLY
ential case.
• Differential side gears and thrust washers
• Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
(2) Lubricate all differential components with hy J9302-36
poid gear lubricant.
Fig. 23 Pinion Gear Head
J
Compensation for depth variance is achieved by
shims placed adjacent to the pinion gear rear bearing
cup (Fig. 2 4 ) .
COLLAPSIBLE
SPACER
BEARING DEPTH
CUP SHIMS J9303-7
C-4171 J9302-7
Fig. 24 Shim Locations Fig. 25 Pinion Rear Bearing Cup installation

If a new gear set is being installed, note the ( + )0.004 inch (0.10mm). Add this amount to the
depth variance etched into both the original and original shim. Or if the old pinion is (-) 3 and the
the replacement pinion gear. Add or subtract new pinion is (-) 2, intersecting figure is (-)0.001 inch
the thickness of the original depth shims to com (0.025mm). Subtract this amount from original shim.
pensate for the difference in the depth vari Refer to the Pinion Gear Depth Variance Chart.
ances. Refer to the Depth Variance charts.
Note where Old and New Pinion Marking columns PINION GEAR ASSEMBLY/INSTALLATION
intersect. Intersecting figure represents plus or mi (1) Place the depth shims (and baffle if equipped)
nus amount needed. in the pinion gear rear bearing bore. Install the bear
For example, if old pinion is plus ( + ) 1 and the ing cup with Installer D-146 and Driver Handle
new pinion is minus (-) 3, intersecting figure is C-4171 (Fig. 25). Ensure cup is correctly seated.
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance -4 -2 -1 0 +1 +2 +3 4-4
+4 + 0.008 + 0.007 +0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 +0.001 0 -0.001 -0.002 -0.003
@ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.0)2 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0004 -0.005 -0.006 -0.007 -0.0)8

J8902-46
J REAR SUSPENSION AND AXLES 3 - 21
(2) Install the pinion front bearing cup with In

staller D-130 and Handle C-4171 (Fig. 26).
SPECIAL T O O L SPECIAL
Fig. 26 Pinion Front Bearing Cup Installation Fig. 28 Collapsible Preload Spacer
(3) Install the rear bearing (and slinger if used) on

the pinion gear with Installer W-262 (Fig. 27).
Fig. 29 Pinion Seal Installation
PINION GEAR CAUTION: Never loosen the pinion gear nut to de
crease the pinion gear bearing preload torque. If the
Fig. 27 Shaft Rear Bearing Installation
specified preload torque i s exceeded, a new col
(4) Install a new collapsible preload spacer on pin lapsible spacer must be installed. T h e torque se
ion shaft and install pinion gear in housing (Fig. 28). quence will have to be repeated.
(5) Install pinion front bearing, oil slinger. Apply a
light coating of gear lubricant on the lip of pinion (8) Use Flange Wrench C-3281 to retain the yoke
seal. Install seal with Installer W-147-E and Handle (Fig. 31). Slowly tighten the nut in small increments
C-4171 (Fig. 29). until the rotating torque is achieved. Measure the
(6) Install yoke with Installer W-162-D and preload torque frequently to avoid over-tightening
the nut. :
Wrench C-3281 (Fig. 30).
(9) Check bearing preload torque with an inch
(7) Install the yoke washer and a new nut on the
pound torque wrench (Fig. 32). The torque necessary
pinion gear. Tighten the nut only enough to remove
to rotate the pinion gear should be;
the end play. Do not over-tighten it. • Original Bearings — 1 to 3 N«m (10 to 20 in. lbs.).
J
>WI * I IMPRRNRK RRI A I
orcvjAL UirrCMIlN IIML
TOOL HOUSING
J9302-24
Fi0. 30 Pinion Yoke Installation Fig. 32 Check Pinion Gear Torque

DIFFERENTIAL
Fig. 31 Tightening Pinion Nut Fig. 33 Differential Bearing Installation

• New Bearings — 2 to 5 N*m (20 to 40 in. lbs.). (4) Install the outboard shim/spacer (selected
thickness) on each side between bearing cup and
DIFFERENTIAL SHIM PACK MEASUREMENT AND housing (Fig. 34). Use 0.142 in. (3.6 mm) as a start
ADJUSTMENT ing point, shim/spacers are available in various
(1) Install the bearings on the hub with Installer thicknesses.
7618 (J-21784) and Driver Handle 8015 (J-8092) (5) Install the marked bearing caps in their correct
(Fig. 33). positions. Install and snug the bolts.
(2) Match each bearing cup with bearing (original). (6) Attach a dial indicator to the housing. Position
Install the cups on the bearings. the indicator plunger so that it contacts the ring gear
(3) Install the differential case in the housing. mating surface (Fig. 35).
RING GEAR INSTALLATION

(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Install new ring gear bolts and alternately
tighten to 61-81 N*m (45-60 ft. lbs.) torque (Fig. 36).
TORQUE
Fig. 36 Ring Gear Bolt Installation

DIFFERENTIAL INSTALLATION
pins seated in the locating holes (Fig. 37). Install the
holddown clamps and tighten the tool turnbuckle fin
ger-tight.
SPECIAL TOOL
W-129-A
Fig. 35 Shim Measurement

(7) Pry the differential case to one side and zero
the dial indicator pointer.
(8) Pry the differential case to the opposite side
and record indicator reading. Reading is additional
shim thickness needed for zero end play. For exam
ple, if reading was 0.008 inch (0.20 mm), an addi
tional 0.004-inch (0.10-mm) thick shim will be
needed at each side zero end play.
(9) Install zero end-play shims on each side of case. (2) Install a pilot stud at the left side of the differ
The differential bearings must be preloaded to ential housing. Attach Dial Indicator to housing pilot
compensate for heat and load during operation. stud. Load the indicator plunger against the opposite
(10) Add an additional 0.004-inch (0.1-mm) to each side of the housing (Fig. 37) and zero the indicator.
outboard shim/spacer for bearing preload.
CAUTION; Do not spread over 0.38 mm {0.015 In). !f BACKLASH AND CONTACT PATTERN ANALYSIS
the housing i s over-separated, it could be distorted (1) Rotate assembly several revolutions to seat
or damaged. bearings. Measure backlash at three equally spaced
locations around the perimeter of the ring gear with
(3) Separate the housing enough to install the case a dial indicator (Fig. 40).
in the housing. Measure the distance with the dial
indicator (Fig. 37).
(5) Install differential and outboard shim/spacer
(selected thickness) in housing.
(6) Install case in the housing. Tap the differential
case to ensure the bearings are fully seated (Fig. 38).
Remove the spreader.
Fig. 40 Ring Gear Backlash Measurement

The ring gear backlash must be within 0.005 -
0.009 inch (0.12 - 0.23 mm). It cannot vary more
than 0.002 inch (0.05 mm) between the points
checked.
If backlash must be adjusted, spacers are available
in various thicknesses. Adjust the backlash accord
ingly (Fig. 41). DO NOT INCREASE THE TOTAL
SHIM PACK THICKNESS, EXCESSIVE BEAR
ING PRELOAD AND DAMAGE WILL OCCUR.
J9302-19
Fig. 38 Differential Installation

(7) Install the bearing caps at their original loca
tions (Fig. 39). Tighten the bearing cap bolts to 77
N«m (57 ft. lbs.) torque.
J9302-28
Fig. 41 Backlash Shim Adjustment

Fig. 39 Differential Bearing Cap Reference Letters
The ring gear teeth contact patterns will show if (2) Scrape the residual sealant from the housing
the pinion gear depth shim(s) have the correct thick and cover mating surfaces. Clean the mating sur
ness. It will also show if the ring gear backlash has faces with mineral spirits. Apply a bead of MOPAR®
been adjusted correctly. The backlash must be main Silicone Rubber Sealant on the housing cover (Fig.
tained within the specified limits until the correct 43). Allow the sealant to cure for a few minutes.
tooth contact patterns are obtained. Install the housing cover within 5 minutes af
(2) Apply a thin coat of hydrated ferric oxide, or
ter applying the sealant. If not installed the seal
equivalent, to the drive and coast side of the ring
gear teeth. ant must be removed and another bead applied.
(3) Rotate the ring gear one complete revolution in (3) Install the cover on the differential with the at
both directions while a load is being applied. Insert a taching bolts. Install the identification tag. Tighten
pry bar between the differential housing and the case the cover bolts to 47 N»m (35 ft. lbs.) torque.
flange. This action will produce distinct contact pat
terns on both the drive side and coast side of the ring CAUTION: Overfilling the differential can result in
gear teeth. the lubricant foaming and overheating.
(4) Note patterns in compound. Refer to (Fig. 42)
for interpretation of contact patterns and adjust ac (4) Refill the differential housing with the speci
cordingly. fied quantity of MOPAR® Hypoid Gear Lubricant.
(5) Install the fill hole plug and tighten to 34 Nmi
FINAL ASSEMBLY (25 ft. lbs.) torque.
(1) Install the axle shafts. Refer to Axle Shaft In
stallation within this group.
J
DRIVE SIDE C O A S T SIDE
OF R I N G O F RING
P A T T E R N S H O U L D BE C E N T E R E D
O N THE DRIVE SIDE O F T O O T H .
H E E ^ ^ ^ ^ ^ ^ ^ T O E T O E ^ ^ ^ ^ ^ ^ ^ ^ E L
PATTERN S H O U L D BE C E N T E R E D ON
T H E COAST SIDE O F T O O T H ,
C O N T A C T PATTERN A N D T O P O F
THE T O O T H .
RING GEAR BACKLASH C O R R E C T

SHIM REQUIRED.
RING GEAR BACKLASH C O R R E C T

SHIM R E Q U I R E D .
Iflf
C O R R E C T D E C R E A S E RING
GEAR B A C K L A S H .
C O R R E C T I N C R E A S E RING
GEAR BACKLASH.
J9003-24
Fig. 42 Gear Tooth Contact Patterns

SEALING CONTOUR O F BEAD

SURFACE
BEAD
THICKNESS
6.35mm ( 1 / 4 J9302-30

AXLE SPECIFICATIONS
MODEL 35 AXLE
Axle Type Semi-Floating, Hypoid Differential Bearing

Preload Shim 0.004 in. 0.1 mm
Application XJ, YJ
Differential Side
Ring Gear Diameter .7.562 in. (19.2 cm) Gear-to-Case Clearance . .0.000-0.006 in. 0.00-0.15 mm
Lubricants*. .MOPAR Gear Lubricant or Ring Gear Blacklash 0.005-0.008 in. 0.12-0.20 mm
Equivalent SAE 75W-90,
API Grade GL-5, M1L-L-2105C Drive Pinion Gearshaft
Bearing Break-Away
•Trailer Tow . . ... . . . . . . . . . Synthetic 80W-140 Preload Torque . . . . . . . . Collapsible Spacer
Lubricant Capacity . .40 oz. (1.1L) Original Bearings . . . . . . 10-20 in. lbs. 1-2 N m
Axle Model Dana M35C Replacement Bearings . . . 15-35 in. lbs. 1.5-4 N m
Axle Ratio. . . . . . . . . . . . . . . . . . . . . . . . .3.07, 3.55, 4.10 Drive Pinion Gear Depth . . . Select Shims
Track ..57.0 Standard Setting ... 2.095 in. 53.2 mm
GAWR ..2700 lbs. Side Gear Clearance (max.). 0.006 in. 0.15 mm
Case Runout ( m a x . ) . . . . . . . 0.002 in. 0.5 m
J9303-34
J
OPERATION
In a conventional differential, the torque applied to
the ring gear is transmitted to the axle shafts
through the differential gears. During normal opera
tion, 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 spin
ning wheel.
In the Trac-lok differential, part of the ring gear
torque is transmitted through clutch packs located
between the differential side gears and case. The
clutch packs contain multiple disc clutches.
In operation, the Trac-lok clutches are engaged by
two concurrent forces. The first being preload force
exerted through Belleville spring washers. The sec
ond is from separating forces generated by the side
gears (Fig. 1).
The Trac-lok design provides the normal differen
tial action needed for turning corners. It also pro
vides for the transmission of equal torque to both
wheels when driving straight ahead. When one
wheel loses traction, the clutch packs transfer torque
to the wheel having the most traction. Trac-lok dif Fig. 1 Limited Slip Differential Operation—Both
ferentials resist wheel spin on bumpy roads. It also Wheels Driving
provides more pulling power when one wheel loses C L E S U P P O R T E D . A L I M I T E D S L I P A X L E CAN E X
traction. Pulling power is continuous until both E R T ENOUGH F O R C E T O C A U S E T H E V E H I C L E TO
wheels lose traction. If both wheels slip due to un MOVE.
equal traction, Trac-lok operation is normal. In ex
treme cases of differences of traction, the wheel with The differential can be tested without removing the
the least traction may spin. This occurs after the differential case from the housing.
Trac-lok has transferred as much torque as possible (1) Raise the vehicle on a hoist with the ignition
to the non-spinning wheel. OFF. Put the transmission in PARK (automatic
transmission) or in first gear (manual transmission).
N O I S E DIAGNOSIS (2) Attempt to turn each rear wheel by hand.
If chatter occurs when turning corners, the most • If difficult or impossible to turn either wheel, the
probable cause is incorrect or contaminated lubri differential IS functioning normally.
cant. Before removing the Trac-lok unit for repair, • If easy to turn the wheel, the differential is NOT
drain, flush and refill the axle with the specified lu functioning normally and should be serviced.
bricant. Eefer to Lubricant change in this Group.
A container of Trac-Lok Lubricant (friction modi DIFFERENTIAL OVERHAUL
fier) should be added after. The Trac-Lok differential components are illus
Vehicles with a limited slip differential should be trated in (Fig. 2). Refer to this illustration during re
road tested by making 10 to 12 slow figure-eight pair service.
turns. This maneuver will pump the lubricant
DISASSEMBLY
through the clutch discs. Service to the Trac-Lok differential requires the
Refer to Group 0, Lubrication and Maintenance for use of Tool Set C-4487 (J-23781). Refer to Model 35
additional information. Axle section in this Group for Differential Removal
and Installation.
DIFFERENTIAL TEST
(1) Clamp one axle shaft in a vise equipped with
WARNING; W H E N SERVICING V E H I C L E S W I T H A soft jaws (Fig. 3).
L I M I T E D S L I P D I F F E R E N T I A L DO NOT U S E T H E E N
(2) Position the differential case on the axle shaft
(Fig. 4). Place shop towels under the differential to
GINE T O T U R N T H E A X L E AND W H E E L S . B O T H
avoid damage during removal of the ring gear (Fig.
R E A R W H E E L S M U S T B E R A I S E D AND T H E VEHI-
4).
DIFFERNTIAL THRUST WASHER

CASE
PINION
SNAP RING
SHAFT
LOCK
PIN
CLUTCH PACK
PINION
MATE
SHAFT J9203-13
Fig. 2 Trac-Lok Differential Components
USE RING GEAR

AXLE BOLTS U P W A R D
SHAFT
AS HOLDING
FIXTURE
(EXTEND N O
MORE THAN
2 3 / 4 IN.)
DIFFERENTIAL
O N AXLE
SHAFT
J8903-42 J8903-43
Fig. 3 Axle Shaft As Holding Fixture Fig. 4 Differential Case On Shaft

(3) Remove and discard the ring gear bolts. Tap (7) Assemble Threaded Adapter C-4487-3 into top
the ring gear with a rawhide mallet and remove side gear. Thread forcing Screw C-4487-2 into
(Fig. 5). adapter until it becomes centered in adapter plate.
(4) Remove the pinion gear mate shaft lock screw (8) Position a small screw driver in slot of
(Fig. 6). Threaded Adapter C-4487-3 (Fig. 9) to prevent
(5) Remove the mate shaft with a drift and ham adapter from turning.
mer (Fig. 7). (9) Tighten forcing screw tool enough to relieve
(6) Install and lubricate Step Plate C-4487-1 (Fig. clutch pack tension. Remove both pinion thrust
8). washers (Fig. 10).
(10) Loosen the forcing screw tool until the clutch
pack tension is relieved.
CASE RING GEAR SPECIAL

TOOL
C-4487-1
RAWHIDE
HAMMER
J9202-76
Fig. 5 Ring Gear Removal
LOWER
DIFFERENTIAL SIDE
CASE GEAR J9203-4
Fig. 8 Step Plate Tool Installation
SOCKET
THREADED
ADAPTER
DISC
C4487-3
PINION GEAR
MATE SHAFT THREADED
^ ^ 9 0 0 3 - 4 4 ROD
C4487-2
Fig. 6 Mate Shaft Lock Screw
PINION MATE SHAFT
DISC
J9203-1
G4487-1
Fig. 9 Threaded Adapter Installation

(12) Remove top side gear and clutch pack. Keep
plates in correct order during removal (Fig. 12).
(13) Remove case from fixture. Remove remaining
DRIFT J9203-60 clutch pack.
(14) Remove clutch pack retaining clips. Mark
Fig. 7 Mate Shaft Removal each clutch pack for installation reference.
(11) Insert Turning Bar C-4487-4 in case. Rotate CLEANING AND INSPECTION
case with tool until pinion gears can be removed (1) Clean all components in cleaning solvent. Dry
(Fig. 11). components with compressed air.
SPECIAL SIDE GEAR DIFFERENTIAL

A N D CLUTCH DISC CASE
Fig. 10 Remove Pinion Thrust Washer
Fig. 12 Side Gear & Clutch Disc Removal

(3) Secure disc packs with retaining clips (Fig. 13).
(4) Position assembled clutch disc packs on the
side gear hubs.
CLUTCH PACK
Fig. 11 Pinion Gear Removal

(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo
nent in either pack is damaged. RETAINER
(3) Inspect side and pinion gears. Replace any gear J8903-50
that is worn, cracked, chipped or damaged.

Fig. 13 Clutch Disc Pack
(4) Inspect differential case and pinion shaft. Re
place if worn or damaged. (5) Position case on axle fixture.
(6) Install clutch pack and side gear in lower bore
ASSEMBLY (Fig. 14). Be sure clutch pack retaining clips remain
(1) The clutch discs are replaceable as complete in position and are seated in the case pockets.
sets only. If one clutch disc pack is damaged, both (7) Install lubricated Step Plate C-4487-1 on first
packs must be replaced. Lubricate each component clutch pack (Fig. 15).
with gear lubricant before assembly and installation. (8) Install the upper side gear and clutch disc pack
(2) Assemble the clutch discs into packs (Fig. 13). (Fig. 15).
LOWER
(11) Install pinion gears. Rotate case with Turning
DIFFERENTIAL SIDE GEAR Bar C-4487-4. Make sure holes of pinion mate gears
CASE AND are aligned with case.
CLUTCH DISC
(12) Tighten forcing screw to compress the
PACK
Belleville plates. Lubricate and install pinion gear
thrust washers with a small screw driver.
ential case.
• Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
(14) Install the pinion mate shaft lock screw with
#
Loctite® on the threads. Tighten the screw to 19 N m
J9003-4 TORQUE
WRENCH
Fig. 14 Clutch Discs & Lower Side Gear Installation
UPPER SIDE
GEAR A N D CLUTCH RING GEAR
DISC PACK BOLT
DIFFERENTIAL
CASE
J9202-77
Fig. 16 Ring Gear Bolt Installation

SPECIAL TOOL
C-4487-1 J9203-6 If replacement gears and thrust washers were
installed, it is not necessary to measure the gear
Fig. 15 Upper Side Gear & Clutch Disc Pack backlash. Correct fit is due to close machining
Installation tolerances during manufacture.
(9) Hold assembly in position. Insert Threaded (15) Invert the differential case and start two ring
Adapter C-4487-3 into top side gear, insert forcing gear bolts. This will provide case-to-ring gear bolt
hole alignment.
Screw C-4487-4.
(16) Install new ring gear bolts and alternately
(10) Tighten forcing screw tool to compress clutch
tighten to 61-81 Iskn (45-60 ft. lbs.) torque (Fig. 16).
discs. (17) Lubricate all differential components with hy
poid gear lubricant.
il REAR SUSPENSION AND AXLES 3 - 33
8 1/4 AXLE
INDEX
page page
Axle Shaft, Seal and Bearing Service 34 Information 33
Axle Specifications 48 Lubricant Change 34
Differential Service 37 Lubricant Specifications 33
Drive Axle Assembly Replacement—XJ Vehicles . 34 Pinion Seal Replacement 36
INFORMATION The differential case is a one-piece design. The dif

The housing consists of an iron differential housing ferential pinion mate shaft is retained with a
with axle shaft tubes extending from either side. The threaded roll pin. Preload and backlash is adjusted
tubes are welded to the housing to form a one-piece by the use of threaded adjusters. Pinion bearing pre
axle. load is set and maintained by the use of a collapsible
The integral type housing, hypoid gear design has spacer.
the centerline of the pinion set below the centerline PINION GEAR DEPTH MEASUREMENT WITH
of the ring gear. GAUGE SET 6575 is used when;
The axle has a fitting for a vent hose used to re • The axle/differential housing is being replaced
lieve internal pressure. • The original pinion depth shim pack is lost or mis
placed
The axle shafts are retained by C-clips in the dif
• Replacing the differential case
ferential side gears.
• Replacing pinion and differential bearings
The removable cover provides a means for servic
ing the differential without removing the axle. LUBRICANT SPECIFICATIONS
The axles have the gear ratio listed on a tag. The Multi-purpose, hypoid gear lubricant should be
tag is attached to the housing cover. used in the 8 1/4 inch axle. The lubricant should
1. DIFFERENTIAL CASE 11. SEAL 21. PINION GEARS

2. DIFFERENTIAL BEARING 12. YOKE 22. THRUST WASHERS
3. BEARING CUP 13. WASHER 23. S H A F T LOCK BOLT
4. P I N I O N GEAR S H A F T 14. NUT 24. MATE SHAFT
5. P I N I O N GEAR DEPTH S H I M S 15. LOCK 25. R I N G G E A R BOLT
6. BEARING CUP 16. ADJUSTER 26. COVER
7. P I N I O N G E A R S H A F T REAR BEARING 17. BEARING CAP 27. PLUG
8. BEARING PRELOAD COLLAPSIBLE SPACER 18. THRUST WASHER 28. RING GEAR
9. DIFFERENTIAL H O U S I N G 19. SIDE GEAR
10. P I N I O N G E A R S H A F T F R O N T BEARING 20. CLOCK J9203-14
Fig. 1 Axle Differential-8 1/4

have MIL-L-2105C and API GL 5 quality specifica (4) Install ABS wiring connections (if equipped) at
J
tions. MOPAR® Hypoid Gear Lubricant conforms to the axle.
both of these specifications. (5) Connect the brake hose at the axle junction
• The factory installed lubricant for the 8 1/4 inch block.
front axle is SAE 80W 90 gear lubricant. (6) Install the shock absorbers to the axle brackets
• The factory installed lubricant quantity is 70 ±1 and tighten to 60 N*m (44 ft. lbs.) torque.
fluid oz. (7) Connect the parking brake cables at the equal
Refer to Group 0, Lubrication and Maintenance for izer or backing plate.
additional information. (8) Connect the vent hose to the tube fitting.
(9) Align the reference marks and connect the
CAUTION: If the axle i s submerged in water, the lu
drive shaft to the axle yoke. Tighten the U-joint
bricant must be replaced immediately. T h i s will s
avoid the possibility of premature axle failure.

clamp bolts to 19 N m (14 ft. lbs.) torque.
(10) Check differential lubricant and add if neces
sary.
DRIVE AXLE ASSEMBLY REPLAGEMENT-XJ (11) Install the wheel and tire.
VEHICLES (12) Bleed the brakes.
REMOVAL
(1) Raise the vehicle. Position support stands un L U B R I C A N T CHANGE
der the frame rails slightly in front the springs. The gear lubricant will drain quicker if the vehicle
(2) Remove the rear wheels. has been recently driven.
(3) Mark the drive shaft yoke and axle pinion yoke (1) Raise and support the vehicle.
for alignment reference. Disconnect the drive shaft (2) Remove the lubricant fill hole plug from the
from the axle. differential housing cover.
(4) Disconnect the axle vent hose. (3) Remove the differential housing cover and
(5) Disconnect the parking brake cables at the drain the lubricant from the housing.
equalizer or backing plate. (4) Clean the housing cavity with a flushing oil,
(6) Disconnect the shock absorbers from the axle light engine oil or lint free cloth. Do not use water,
brackets. steam, kerosene or gasoline for cleaning.
(7) Disconnect the brake hose at the axle junction
block. Do not disconnect the wheel cylinder tub CAUTION: DO N O T F L U S H Sure-Grip differentials.
ing fittings. Sure-Grip differentials may be cleaned only by wip
(8) If equipped, disconnect ABS wiring connections ing with clean, lint-free cloths.
at the axle.
(9) Support the axle with a hydraulic jack under (5) Remove the sealant from the housing and cover
the differential. surfaces. Use solvent to clean the mating surfaces.
(10) Remove the spring U-bolts from the plate (6) Apply a bead of MOPAR® Silicone Rubber Seal
brackets. ant to the housing cover (Fig. 2). Allow the sealant
to cure for a few minutes.
(11) Lower the jack enough to remove the axle. Install the housing cover within 5 minutes after
applying the sealant. If not installed the sealant
INSTALLATION
must be removed and another bead applied.
CAUTION: All suspension components that use rub (7) Install the cover and any identification tag.
ber bushings should be tightened with the vehicle Tighten the cover bolts in a criss-cross pattern to 47
at the normal height. It i s important to have the N*m (35 ft. lbs.) torque.
springs supporting the weight of the vehicle when (8) Refill the differential with MOPAR® Hypoid
the fasteners are torqued. If the springs are not at Gear Lubricant within 13 mm (1/2 in.) below the fill
their normal ride position, vehicle ride comfort plug hole. With Sure-Grip differentials, add a con
could be affected. B u s h i n g s must never be lubri tainer of MOPAR® Hypoid Gear Lubricant Additive.
cated. (9) Install the fill hole plug and lower the vehicle.
(1) Support the axle on a hydraulic jack under the AXLE SHAFT, SEAL AND BEARING SERVICE
differential. Position the axle under the vehicle.
(2) Raise the axle and align the spring center bolts CAUTION: When rear axle service i s necessary,
with the locating holes in the axle pads and plate both rear wheels must be raised off the surface s o
brackets. that they are free to rotate. Be cautious when the
(3) Install the spring U-bolts through the plate tires are being rotated by the engine or by other
#
brackets and tighten to 70 N m (52 ft. lbs.) torque. means.
J REAR SUSPENSION AND AXLES 3 - 3§
SEALING CONTOUR OF BEAD

CAUTION; If equipped with a Sure-Grip differential,
do not rotate either axle shaft unless both are prop
erly in place. Rotation of one axle shaft without the
other being installed can result in misalignment of
the side gears/splines. T h i s will necessitate side
gear re-alignment before the axle shaft can be i n
stalled.
Fig. 4 Axle Shaft C-Clip Lock

AXLE SHAFT REMOVAL
(1) Raise and support the vehicle. contact on the shaft will be a dull gray and i t
(2) Remove the wheel and tire. could appear to be lightly dented,
(3) Remove the brake drum. (10) If any of these conditions exist, the axle shaft
(4) Clean all the foreign material from housing and bearing must be replaced.
cover area. The normal appearance (from roller bearing
(5) Loosen the housing cover bolts and drain the contact) will be a dull gray surface area that
lubricant from the housing. Remove the housing could appear slightly dented.
cover.
AXLE SHAFT SEAL AND REARING REMOVAL
(6) Rotate the differential case so that the pinion
(1) Remove the axle shaft seal with a small pry
mate gear shaft lock screw is accessible. Remove the
bar.
lock screw and the pinion mate gear shaft from the
(2) Remove the bearing if it appears damaged or
case (Fig. 3).
the axle shaft shows any of the conditions described
(7) Push the axle shaft in toward the center of the
above.
vehicle. Remove the axle shaft C-clip lock from the
(3) Remove the bearing with Remover C-4167 (Fig.
axle shaft (Fig. 4).
5). Attach Slide Hammer 7420 and Adapter 7420-8 to
(8) Remove the axle shaft. Use care to prevent
the end of the removal tool.
damage to the axle shaft bearing, which will remain
(4) Inspect the axle shaft tube bore for roughness
in the axle shaft tube.
and burrs. Remove as necessary.
(9) Inspect the axle shaft bearing contact surface
area for indications of brinelling, spalling, and pit CAUTION; Inspect the housing bore for burrs. Re
ting. move them if they exist.
If any of these conditions exist, the axle shaft
and bearing should be replaced. Normal bearing
SPECIAL T O O L
(Fig. 4). Push the axle shaft outward to seat the
SPECIAL T O O L
7420 C-4167 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.
Tighten the screw to 11 N*m (8 ft. lbs.) torque (Fig.
3).
(4) Clean the cover and apply a bead of sealant.
Refer to the Drain and Refill in this section.
(5) Install the brake drum and wheel and tire.
AXLE
SHAFT (6) Raise or lower the hoist until the vehicle is
ADAPTER
TUBE level.
SPECIAL T O O L (7) Remove the fill hole plug. Fill the differential
7420-8 J9103-30 housing with lubricant. Refer to the Specifications
chart for the type and the quantity. Install the fill
Fig. 5 Axle Shaft Bearing Removal hole plug.
BEARING AND SEAL INSTALLATION (8) Lower the vehicle and test the brakes and axle
Do not install the original axle shaft seal. Al for correct operation.
ways install a new seal.
(1) Wipe the bore in the axle shaft tube clean. PINION SEAL REPLACEMENT
(2) If the original bearing is not reusable, install a
CAUTION: T h e following procedures must be used
new bearing. Place the axle shaft bearing on the pi
so the correct pinion bearing preload torque i s re
lot of Bearing Installer C-4198 and Handle C-4171.
tained. If this procedure i s not completely followed,
CAUTION: DO NOT use the new axle shaft seal to the result can be premature failure of the rear axle.
position or seat the bearing in the axle shaft bore.
REMOVAL
(3) Insert the bearing into the tube. Ensure that (1) Raise and support the vehicle.
the bearing is not cocked and is seated firmly against (2) Mark the U-joint, pinion yoke, and pinion shaft
the tube shoulder. for reference.
(4) Install the new axle shaft seal (Fig. 6) with In (3) Disconnect the drive shaft from the pinion
staller C-4198 and Handle C-4171. The flat side of yoke. Secure the drive shaft in an upright position to
the installation tool must face the seal. prevent damage to the rear U-joint.
(4) Remove the rear wheels and brake drums to
SPECIAL T O O L SPECIAL T O O L prevent any drag. The drag can cause a possible false
C-4171 C-4198 bearing preload torque measurement.
(REVERSED)
(5) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload. Ro
tate the pinion shaft several times with the torque
wrench. Note the indicated torque as the wrench is
moved through several revolutions.
This measurement is very important because
the bearing preload torque must be carefully re
adjusted after the new seal is installed.
J9103-31 (6) Retain the yoke with Wrench C-3281. Remove
the pinion shaft nut and Belleville washer.
Fig. 6 Axle Shaft Seal Installation (7) Remove the yoke with a puller.
(5) When the tool contacts the end of the tube (8) Lower the rear of the vehicle to prevent lubri
(face), the seal will be at the correct position and cant leakage.
depth. (9) Remove the pinion shaft seal with Puller
C-748. Clean the seal contact surface in the housing
AXLE SHAFT INSTALLATION bore.
(1) Lubricate the bearing bore and seal lip. Insert
the axle shaft and engage the splines with the side INSTALLATION
gear. Use care to prevent the shaft splines from dam (1) Examine the splines on the pinion shaft for
aging the axle shaft seal lip. burrs or wear.
(2) Insert the C-clip lock in the recessed groove (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.
The outer perimeter of the seal is pre-coated
with a special sealant. An additional application
of sealant is not required.
(4) Install the replacement pinion shaft seal (Fig.
7) with Seal Installer C-4076-A and Handle
C-4735-1.
The seal is correctly installed when the seal
flange contacts the face of the differential hous
ing flange.

binding condition. This condition must be cor
rected before the installation of the drive shaft.
(10) If the specified torque is not obtained, tighten
the nut in small increments until the preload torque
is obtained.
(11) The seal replacement is unacceptable if the fi
nal nut torque is less than 285 N»m (210 ft. lbs.)
Fig. 7 Pinion Shaft Seal Installation
torque.
(5) Position the pinion yoke on the end of the shaft (12) Install the drive shaft with the installation
with the reference marks aligned. reference marks aligned. Tighten the U-joint yoke
(6) Seat the yoke on the pinion shaft with Installer clamp screws to 19 N-m (14 ft. lbs./170 in. lbs.)
C-3718 and Wrench C-3281. torque.
(7) Remove the tools. Install the Belleville washer. (13) Install the brake drums and wheel and tire.
The convex side of the washer must face outward.
(14) Adjust the hoist so that the vehicle is in a
(8) Retain the pinion yoke with Wrench C-3281.
level position. Check the differential housing lubri
Tighten the shaft nut to 285 N-m (210 ft. lbs.) torque
cant level. If necessary, add MOPAR® Hypoid Gear
(Fig. 8). Rotate the pinion shaft several complete rev
olutions to ensure that the bearing rollers are seated. Lubricant.
Use a Newton-meter or an inch-pound torque
wrench to measure the pinion gear bearing pre DIFFERENTIAL SERVICE
load torque. SERVICE INFORMATION
It is not necessary to remove the complete axle to
CAUTION: Never loosen the pinion gear nut to de
service the differential.
specified preload torque i s exceeded, a new col
CAUTION: When differential service i s necessary,
lapsible spacer must be installed. T h e torque se
both rear wheels must be raised off the surface.
quence will have to be repeated.
They must be free to rotate.
(9) Continue tightening and measuring the bear
ing preload torque until the it is the same as the CAUTION: Do not subject the bearings, cups, bores
original. The bearing preload torque should
or journals to heat from a torch or other abuse.
never be greater than 1 N»m (10 in. lbs.) more
Otherwise permanent damage could result. Special
than the recorded value.
tools are available and recommended when servic
The bearing preload torque should be constant
ing an axle.
during a complete revolution of the pinion gear.
If the preload torque varies, this indicates a
DIFFERENTIAL CASE REMOVAL

(1) Remove the axle shafts, refer to Axle Shaft Re
moval.
Side play and runout checks taken during dis
assembly will be very useful in reassembly.
(2) Measure for differential side play. Position a
screwdriver or pinch bar between left side of axle
housing and case flange (Fig. 9). Use a prying motion
to determine if any side play exists. There should be
no side play.
RING GEAR
Fig. 10 Ring Gear Runout Measurement
J9003-55
Fig. 9 Differential Case Side Play Test

Side play resulting from bearing races being
loose on case hubs require replacement of the Fig. 11 Housing & Caps Marked For Installation
differential case. Otherwise, use threaded ad Reference
juster to remove the side play before measuring (6) Remove the bearing threaded adjuster lock
the ring gear runout. from each bearing cap. Loosen the bolts, but do not
(3) Eliminate any side play in the differential case. remove the bearing caps.
Attach Dial Indicator to Pilot stud C-3288-B. Place (7) Loosen the threaded adjusters with Wrench
the indicator plunger at a right angle (90°) to the C-4164 (Fig. 12).
ring gear (Fig. 10). The plunger should exert a slight (8) Hold the differential case in place. Remove the
force against the gear face. bearing caps (Fig. 13), adjusters and the differential
(4) Measure the runout by turning the ring gear case.
several complete revolutions. Observe the dial indica Each differential bearing cup and threaded ad
tor pointer. Mark the ring gear and the differential juster must be kept with their respective bearing.
case at the areas of maximum runout. The ring gear
runout should not exceed 0.005 inch (0.13 mm). If the PINION GEAR SHAFT REMOVAL
runout exceeds 0.005 inch (0.13 mm), a damaged dif (1) Remove the pinion gear nut and washer. Use
ferential case could be the cause. Puller C-452 and Wrench C-3281 to remove the pin
The marking on the differential case will be ion gear yoke.
very useful later during the differential case (2) Use Puller C-748 to remove the pinion seal.
runout. Discard the seal.
(5) Mark the differential housing and the differen (3) Force the pinion gear out the front bearing to
tial bearing caps for installation reference (Fig. 11). remove the shaft and front bearing. This will dam
age the front bearing rollers and bearing cup.
SPECIAL
TOOL
G293-PA
Fig. 12 Threaded Adjuster Tool

BEARING
CUP
Fig. 14 Inner Bearing Removal

(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case
pilots. Remove the ring gear.
CASE FLANGE RUNOUT MEASUREMENT

(1) If the ring gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should also be mea
sured. Install the case with the bearing cups and the
threaded adjusters close to their original position.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 (Fig. 12) to thread
both adjusters inward. Remove all side play.
BEARING DIFFERENTIAL (3) Attach Dial Indicator to measure the flange
CAP CASE J9003-86 runout. The plunger should contact the ring squarely
between the outer edge and the gear attaching bolt
Fig. 13 Differential Bearing Cap Removed holes (Fig. 15).
The front bearing and cup must be replaced.
Discard the bearing collapsible spacer.
(4) Remove the front and rear bearing cups.
• Front bearing cup use Remover C-4345 and Han
dle C-4171
• Rear bearing cup use Remover C-4307 and Handle
C-4171
(5) Remove the rear bearing from the pinion shaft
with Puller C-293-PA (J-29721) and Adapter
C-293-42 (Fig. 14). Remove and record the pinion
gear depth shims.
RING GEAR
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). Use a vise equipped with soft jaws (brass). Fig. 15 Case Flange Runout Measurement
(4) Rotate the differential ease several times. Ob Replace bearings and cups if either is galled, worn,
serve the dial indicator pointer. Mark the area of cracked, or damaged.
maximum flange runout. The differential case flange (4) Inspect the differential side and pinion gears.
runout must not exceed 0.003 inch (0.08 mm). If the Replace any gear that is worn, cracked or chipped.
runout exceeds the amount replace the differential (5) Inspect the differential case. Replace the case if
case. cracked or damaged.
You can reduce excessive ring gear runout by Polish each axle shaft with No. 600 crocus
positioning the ring gear runout mark 180 de cloth. This can remove slight surface damage.
grees opposite the flange runout mark. Do not reduce the diameter of the axle shaft seal
(5) Remove the differential bearing cap bolts. Re contact surface. When polishing, the crocus
move the differential case from the differential hous cloth should be moved around the circumfer
ing. ence of the shaft (not in-line with the shaft).
When replacing a drive pinion gear bearing,
DIFFERENTIAL CASE DISASSEMBLY always replace the bearing and cup as a
(1) Rotate the side gears until the pinion gears are matched set only.
located at the differential case opening and remove (6) Inspect the axle shaft C-clip locks for cracks
them. and excessive wear. Replace them if necessary.
(2) Remove the side gears and the thrust washers. (7) Test each threaded adjuster to determine if it
(3) Remove the differential bearings from the case rotates freely.
hubs with Puller C-293-PA, Adapter C-293-48 and (8) If an adjuster binds, repair the damaged
Plug SP-3289 (Fig. 16). threads or replace the adjuster.
ADAPTERS
DIFFERENTIAL CASE ASSEMBLY
(1) Lubricate all the differential case components
with gear lubricant.
(2) Place the thrust washers on the differential
side gears. Position the gears in the differential case
counterbores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear
ance Measurement And Adjustment (Fig. 17).
SIDE G E A R CLEARANCE 0.007
T H R U S T WASHER THICKNESS +0.033
TOTAL 0.040
I 0.040
REPLACEMENT WASHER THICKNESS -0.037
N E W SIDE G E A R CLEARANCE 0.003
J9203-31
Fig. 17 Side Gear Calculations

(3) Position the thrust washers on the differential
pinion gears. Mesh the pinion gears with the side
gears.Ensure that the pinion gears are exactly
180 degrees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align these components with the
mate shaft bores in the case.
(5) If the ring gear was removed, clean all contact
surfaces. Use an Arkansas stone or fine file to re
move any sharp areas from the chamfered inside di
Fig. 16 Differential Bearing Removal ameter.
CLEANING/INSPECTION (6) If removed, heat ring gear with a heat lamp or
(1) Clean all of the differential components in by immersing in a hot fluid. The temperature should
cleaning solvent. Allow the bearings to either air dry not exceed 149°C (300°F). Do not use a torch to
or dry them with a lint-free cloth. Dry the other com heat the ring.
ponents with compressed air. (7) Position heated gear on case. Use two equally
(2) Examine each component for wear or damage. spaced Pilot Studs C-3288-B to align the gear with
(3) Replace shims, bearings and cups as a set only. the flange holes (Fig. 18).
DRIVE P I N I O N G E A R S H A F T
J9203-24
Fig. 18 Case-To-Ring Gear Alignment Fig. 20 Axle Adjustment Tools—8 1/4

(8) Install replacement ring gear bolts (with left (3) Install rear (inner) bearing cup use Installer
hand threads). Alternately and evenly tighten each C-4308 and Handle C-4171.
bolt to 95 N-m (70 ft. lbs.) torque. Assemble tools as described;
• Position Spacer (SP-6030) over Shaft (SP-5385)
CAUTION: When installing a differential bearing, • Position pinion rear bearing on shaft
never apply force to the bearing cage because bear • Position tools (with bearing) in the housing
ing damage will result. • Install Sleeve (SP-5382)
• Install pinion front bearing
(9) Place a differential bearing on each hub with
• Install Spacer (SP-6022)
Installer C-4340 and Handle C-4171 (Fig. 19).
• Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193)
(4) Prevent compression sleeve tool from turning
with Wrench C-3281.
Tighten the nut to seat the pinion bearings in the
housing (Fig. 21). Allow the sleeve to turn several
times during the tightening to prevent brinelling the
bearing cups or the bearings.
J92Q3-25
Fig. 19 Differential Bearing Installation

PINION DEPTH MEASUREMENT AND
ADJUSTMENT WITH GAUGE SET 6575
Fig. 21 Seating Pinion Bearings
(1) Use pinion gear adjustment gauge set 6575
(Fig. 20) and continue the assembly: Depth shim(s) are positioned between the pin
(2) Install front (outer) bearing cup use Installer ion gear rear bearing and pinion gear to provide
D-130 and Handle C-4171. the separation distance. The required thickness
3 - 42 REAR SUSPENSION AND AXLES — — — — — . ^ J
(8) Center the tool. Place a piece of 0.002 inch

shim stock at each end of the arbor tool. Position the
bearing caps on the arbor tool. Install the attaching
bolts. Tighten the cap bolts to 14 N-m (10 ft. lbs.)
torque.
(9) Trial fit depth shim(s) between the crossbore
arbor tool and gauge block tool (Fig. 22). The depth
shim(s) fit must be snug but not tight (drag fric
tion of a feeler gauge blade).
Depth shims are available in 0.001-inch incre
ments from 0.020 inch to 0.038 inch.
(10) Note the etched number on the face of the
drive pinion gear. The numbers represent thousands-
of-an-inch deviation from the standard. If the num
ber is - (negative), add that value to the required
thickness of the depth shim(s). If the number is +
Fig. 22 Depth Shim(s) Selection (positive), subtract that value from the thickness of
of the depth shim(s) is determined according to the depth shim(s). If the number is 0, no change is
the following information, necessary.
(5) Loosen the compression nut tool. Lubricate the (11) Remove the tools from the differential hous
pinion gear front and rear bearings with gear lubri ing.
cant. Re-tighten the compression nut tool to 1 to 3 (12) Position the depth shim(s) on the pinion gear.
Nun (15 to 2 5 in. lbs.) torque. Rotate the pinion gear Install the rear bearing with Installer C-4040 (Fig.
several complete revolutions to align the bearing 23). Be sure the contact surfaces are clean and with
rollers. out foreign particles.
(6) Install Gauge Block. (13) Lubricate the pinion gear front and rear bear
• 8 1/4 axles (Fig. 21) ings with gear lubricant.
• Install Gauge Block SP-5383 at the e n d of SP-5385 (14) Install the pinion gear in the housing. Install
• Install Cap S c r e w (SP-536) a n d tighten the new collapsible spacer at the end of the pinion
(7) Position Crossbore Arbor (SP-6029) in the dif gear. Install the pinion gear front bearing.
ferential housing (Fig. 22). (15) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281 (Fig. 24).
Original P i n i o n Replacement Pinion Gear Depth Variance

Gear Depth
Variance -4 -2 -1 0 4-1 +2 +3 +4
+4 + 0.008 + 0007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+ 3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
i + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-1 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
Fig. 25 Pinion Gear Seal Installation

(19) Remove the tools. Install the 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 drive pinion gear shaft nut enough
Fig. 23 Shaft Rear Bearing Installation
to remove the bearing end play. While tightening, ro
It is necessary to use the tools (above) to cor tate the pinion shaft to ensure the bearing rollers are
rectly seat the front bearing on the drive pinion correctly seated.
gear shaft (Fig. 24). (21) Tighten the pinion nut (Fig. 26) to 285 N-m
(210 ft. lbs.) torque (minimum).
Fig. 24 Pinion Yoke Installation

CAUTION. Use care to prevent collapsing preload
collapsible spacer during installation of the yoke
and seating the front bearing.
(16) Remove yoke and tools from the pinion gear.

(17) Install the pinion seal with Seal Installer Fig. 26 Tightenihg Pinion Gear Nut
C-4076-A and Handle C-4735-1 (Fig. 25). (22) Remove the tools from the shaft. Rotate the
The outer perimeter of the seal is pre-coated pinion several revolutions to seat the bearing rollers.
with a special sealant. An additional application
of sealant is not required.
(18) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281.
CAUTION; Never loosen the pinion gear nut to de

specified preload torque is exceeded, a replacement
collapsible spacer must be installed. The torque se
quence will have to be repeated.
(23) Measure the pinion bearing preload torque by

rotating pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct bearing pre
load torque is 1 to 2 Nun (10 to 20 in. lbs.). This
torque value is with replacement bearings and pinion
nut tightened with a minimum of 285 Nun (210 ft.
lbs.) torque (Fig. 27).
When using original pinion rear bearing and a
replacement front bearing. The correct preload
torque is 1 Nun (10 in. lbs.) torque in addition to
the torque measured and recorded during disas
Fig. 28 Bearing Caps & Bolts
sembly.
(3) Install the bearing cap bolts (Fig. 28). Tighten
the upper bolts to 14 Nun (10 ft. lbs.) torque. Tighten
the lower bolts finger-tight until the bolt head is
lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING

GEAR BACKLASH ADJUSTMENT
The following limitations must be considered when
adjusting the differential:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm).
• Mark the gears so the same teeth are meshed dur
ing all backlash measurements.
• Maintain the specified threaded-adjuster torque
while adjusting.
• Excessive adjuster torque will introduce a high
Fig. 27 Bearing Preload Torque Measurement bearing load and cause premature bearing failure.
Insufficient adjuster torque can result in excessive
The bearing preload torque should be constant
differential case free-play and ring gear noise.
during a complete revolution of the drive pinion
gear shaft. If the preload torque varies during • Insufficient adjuster torque will not support the
rotation of the shaft, there is an internal binding ring gear correctly and can cause excessive differen
that must be corrected before final assembly. tial case free-play and ring gear noise.
(24) If the specified torque is not obtained, tighten The differential bearing cups will not always
the nut in small increments until the preload torque immediately follow the threaded adjusters as
is obtained. they are moved during adjustment. Ensure accu
The differential will be unacceptable for use if rate bearing cup responses to the adjustments.
the final nut torque is less than 285 Nun (210 ft. Maintain the gear teeth engaged (meshed) as
lbs.) torque. If the preload torque is not within marked. The bearings must be seated by rapidly
the specified range this is also unacceptable. rotating the pinion gear a half turn back and
forth. Do this five to ten times each time the
DIFFERENT/ML CASE INSTALLATION threaded adjusters are adjusted.
(1) Apply a coating of hypoid gear lubricant to the (1) Use Wrench C-4164 to adjust each threaded ad
differential bearings, bearing cups and threaded ad juster inward (Fig. 29) until the differential bearing
justers. A dab of grease can be used to keep the ad free-play is eliminated. Allow some ring gear back
justers in position. Carefully position the assembled lash (approximately 0.01 inch/0.25 mm) between the
differential case in the housing. ring and pinion gear. Seat the bearing cups with the
(2) Observe the reference marks and install the procedure described above.
differential bearing caps at their original locations (2) Install Dial Indicator (Fig. 30). Position the
(Fig. 28). plunger against the drive side of a ring gear tooth.
4 REAR SUSPENSION AND AXLES 3 - 45
Continue to tighten the right-side adjuster and seat

bearing cups until the torque remains constant at 95
N-m (70 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.005 to 0.008 inch (0.127 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is ob
tained.
The left-side threaded adjuster torque should
have approximately 95 Nun (70 ft. lbs.) torque. I f
the torque is considerably less, the complete ad
justment procedure must be repeated.
(8) Tighten the left-side threaded adjuster until 95
Nun (70 ft. lbs.) torque is indicated. Seat the bearing
rollers with the procedure described above. Do this
Fig. 29 Threaded Adjuster Tool until the torque remains constant.
(9) Install the threaded adjuster locks . Ensure the
Measure the backlash at 4 positions (90 degrees lock finger is engaged with the adjuster hole.
apart) around the ring gear. Locate and mark the Tighten the lock screws to 10 Nun (90 in. lbs.)
area of minimum backlash. torque.
(3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash SIDE GEAR CLEARANCE MEASUREMENT AND
measurements will be taken with the same gear ADJUSTMENT
teeth meshed. When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install the axle shafts and C-clip locks and pin
ion mate shaft. If necessary, refer to the installation
located within this group.
(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 3D.
Fig. 30 Ring Gear Backlash Measurement

(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.003 to 0.004
inch (0.076 to 0.102 mm) with each adjuster tight
ened to 14 Nun (10 ft. lbs.) torque. Seat the bearing Fig. 31 Side Gear Clearance Measurement
cups with the procedure described above.
(3) If side gear clearances is no more than 0.005
(5) Tighten the differential bearing cap bolts to
inch. Determine if the shaft is contacting the pinion
136 Nun (100 ft. lbs.) torque.
(6) Use Wrench C-4164 to tighten the right-side gear mate shaft. Do not remove the feeler gauges,
threaded adjuster to 95 N»m (70 ft. lbs.) torque. Seat inspect the axle shaft with the feeler gauge in
the bearing cups with the procedure described above. serted behind the side gear. If the end of the axle
shaft is not contacting the pinion gear mate shaft, RING GEAR TEETH CONTACT PATTERN
the side gear clearance is acceptable. ANALYSIS
(4) If clearance is more than 0.005 inch (axle shaft The ring gear teeth contact patterns will show if
not contacting mate shaft), record the side gear clear the pinion gear depth shim(s) have the correct thick
ance. Remove the thrust washer and measure its ness. It will also show if the ring gear backlash has
thickness with a micrometer. Add the washer thick been adjusted correctly. The backlash must be main
ness to the recorded side gear clearance. The sum of tained within the specified limits until the correct
gear clearance and washer thickness will determine teeth contact patterns are obtained.
required thickness of replacement thrust washer • Excessive backlash is corrected by moving the ring
(Fig. 32). gear teeth closer to the pinion gear teeth
• Insufficient backlash is corrected by moving the
SIDE G E A R CLEARANCE 0.007
T H R U S T WASHER THICKNESS + 0.033
ring gear away from the pinion gear
TOTAL 0.040 (1) Apply yellow ferrous (iron) oxide compound to
I 0.040
both sides of ring gear teeth.
REPLACEMENT WASHER THICKNESS -0.037 (2) Rotate the ring gear one complete revolution in
N E W SIDE G E A R CLEARANCE 0.003 both directions.
J9203-31 (3) Note patterns in compound. Refer to (Fig. 33)
for interpretation of contact patterns and adjust ac
Fig. 32 Side Gear Calculations cordingly.
In some cases, the end of the axle shaft will move (4) Install the axle shafts. Refer to Axle Shaft In
and contact the mate shaft when the feeler gauge is stallation within this group.
inserted. The C-clip lock is preventing the side gear (5) Install the housing cover. Refill the differential
from sliding on the axle shaft. with lubricant. Refer to Axle Shaft Installation.
(5) If there is no side gear clearance, remove the
C-clip lock from the axle shaft. Use a micrometer to
measure the thrust washer thickness. Record the
thickness and re-install the thrust washer. Assemble
the differential case without the C-clip lock installed
and re-measure the side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
DRIVE S I D E COAST SIDE

O F RING O F RING
PATTERN S H O U L D BE C E N T E R E D
O N T H E DRIVE S I D E O F T O O T H .
HEEL TOE TOE HEEL
PATTERN S H O U L D BE C E N T E R E D O N
T H E COAST SIDE O F T O O T H ,
CONTACT PATTERN AND T O P O F
THE T O O T H .
RING GEAR BACKLASH CORRECT.

SHIM REQUIRED.
RING GEAR BACKLASH CORRECT.

SHIM REQUIRED.
CORRECT. D E C R E A S E R I N G
GEAR BACKLASH.
CORRECT. I N C R E A S E RING
GEAR BACKLASH.
J9003-24
Fig. 33 Gear Teeth Contact Patterns

AXLE SPECIFICATIONS
8 1/4 AXLE
Axle Type Semi-floating, hypoid Differential Bearing

Preload . 70 ft. lbs. 95 N m
Application XJ Vehicles
Differential Side
Ring Gear Diameter 8.25 in. (20.95 cm) Gear-to-Case Clearance . . 0.005 in. 0.12 mm
Lubricants MOPAR Gear Lubricant or Ring Gear Blacklash . . . . . . 0.005-0.008 in. 0.12-0.20 mm
equivalent SAE 75W-90,
API Grade GL-5 quality, Drive Pinion Gearshaft
MIL-L-2105C Bearing Break-Away
Preload Torque . . . . 10-20 in. lbs. 1-2 N-m
Lubricant Capacity 4.4 pt. (2.08 L)
Drive Pinion Gear Depth . . . Select shims
AXLE RING/PINION Case Runout (max.) . 0.003 in. 0.07 mm

RATIO GEAR T O O T H C O M B I N A T I O N S
Ring Gear Back Face Runout.. 0.005 in. 0.127 mm
3.07:1 43/14
3.55:1 39/11
4.10:1 41/10
J9303-35
SURE-GRIP DIFFERENTIAL
GENERAL INFORMATION SERVICE INFORMATION
The Sure-Grip differential is an option available in When Sure-Grip differential service is necessary,
the 8 1/4 rear axles (Fig. 1). both rear wheels must be raised off the surface so
Except for the Sure-Grip differential case, all axle that they are free to rotate.
components are identical to the standard 8 1/4 axle. A Sure-Grip differential case is not repairable. If
The Sure-Grip has a two-piece differential case. The defective, it must be replaced as a complete unit
case is completely interchangeable with a standard only. Do not attempt to disassemble and repair the
differential case (Fig. 1). Sure-Grip differential re case components.
moval and installation is the same as the Standard Follow the procedure outlined under Standard Dif
differential. ferential for service.
DIFFERENTIAL DIFFERENTIAL TEST
CASE
SIDE GEAR CAUTION: R A I S E B O T H R E A R W H E E L S off the sur

face anytime the differential i s to be rotated by the
PINION
GEAR
engine (or by another means).
(1) Position the vehicle on a hoist. Place the trans

mission selector lever in PARK (automatic transmis
sion) or in first gear (manual transmission). Make
sure the ignition is OFF.
(2) Attempt to manually rotate each rear wheel.
Grip the tire tread area and apply a rotating force
with your hands.
COIL S P R I N G
(3) If hard to turn the tire the differential is func
CLUTCH tioning normally. If relatively easy, the differential
is not functioning normally and should be replaced.
A Sure-Grip differential case is not repairable. If
LUBRICATION defective, it must be replaced as a complete unit
GROOVES only. Do not attempt to disassemble and repair the
case components.
LUBRICATION
WELL J9003-120
DIFFERENTIAL NOISE
Fig. 1 Sure-Grip Differential Noise complaints involving a Sure-Grip should be
evaluated to determine the source of the noise. If a
The action of a standard differential will allow the noise occurs while the vehicle is turning, the proba
rear wheels to rotate at different speeds when the ve ble cause is incorrect or insufficient gear lubricant.
hicle is turning. This differential will divide the en The drain and clean procedure should be used for
gine torque equally between them. This is a normal possible elimination of the noise before replacing the
function of a differential. A Sure-Grip differential differential.
transfers additional engine torque to the rear wheel
that has the better traction surface. The Sure-Grip WARNING; W H E N SERVICING V E H I C L E S WITH
differential allows the driving wheel with better trac S U R E - G R I P , DO N O T U S E T H E ENGINE T O R O T A T E
tion to develop more driving torque than the other T H E A X L E AND W H E E L S . B O T H R E A R W H E E L S
wheel. The Sure-Grip is not a locking type differen M U S T B E R A I S E D AND T H E V E H I C L E S U P P O R T E D .
tial. A S U R E - G R I P A X L E CAN E X E R T ENOUGH F O R C E
(IF ONE W H E E L I S IN CONTACT W I T H T H E S U R
IDENTIFICATION FACE) TO C A U S E T H E V E H I C L E T O MOVE.
Raise both rear wheels off the surface and rotate
them. If both rear wheels rotate in the same direc
tion, the vehicle is equipped with a Sure-Grip differ LUBRICATION
ential. Another method of identification is by When refilling a Sure-Grip differential a container
removing the housing cover fill hole plug. Examine of MOPAR® Hypoid Gear Additive should be added.
(with a flashlight) the differential case components Refer to Group 0, Lubrication and Maintenance for
through the lubricant fill hole. additional information.
XJ REAR SUSPENSION COMPONENTS REAR AXLE MODEL 35
DESCRIPTION TOftQUi DESCRIPTION TORQUE
Jounce Bumper to Frame S c r e w . . . . 20 N-m (15 ft. lbs.)

Shock Absorber Upper Screws 20 N-m (15 ft. lbs.) Bearing Cap Bolts 77 N m (57 ft. lbs.)
Shock Absorber Lower N u t . . . . . . . 60 N m (44 ft. lbs.) Differential Cover Bolts . 47 N-m (35 ft. lbs.)
Spring U-bolt/Stud Nut 70 N-m (52 ft. lbs.) Fill Hole Plug . . 34 N m (25 ft. lbs.)
Spring Front Pivot Bolt 88 N-m (65 ft. lbs.) Ring Gear Bolts. 61 to 81 N m
Spring Rear Shackle Bolt 88 N-m (65 ft. lbs.) (45 to 60 ft. lbs.)
Stabilizer Bar Link Screw 12 N-m (9 ft. lbs.)
Stabilizer Bar Link Axle J9303-12
Bracket Nut . . . . . . . 74 N-m (55 ft. lbs.)
Stabilizer Bar Clamp Screws 54 N-m (40 ft. lbs.)
Wheel Lug Nut Vi x 20 with REAR AXLE 8 1/4 INCH
60° Cone 109 to 150 N-m
(80 to 110 ft. lbs.)
J9303-30 DESCRIPTION TORQUE
Bearing Cap Bolt 95 N m (70 ft. lbs.)

Brake Backing Plate 64 N-m (48 ft. lbs.)
YJ REAR SUSPENSION COMPONENTS Differential Housing Cover Bolt 47 N-m (35 ft. lbs.)
Pinion Yoke Nut (Minimum Torque). . . 285 N-m (210 ft. lbs.)
Ring Gear Bolt 95 N-m (70 ft. lbs.)
DESCRIPTION TORQUE Wheel Lug Nut Vi x 20 with
60° Cone. . 109 to 150 N-m
Jounce Bumper to Frame S c r e w . . . . 41 N-m (30 ft. lbs.) (80 to 110 ft. lbs.)
Shock Absorber Lower B o l t . . . . . . . 60 N-m (44 ft. lbs.)
Shock Absorber Upper Nut 60 N-m (44 ft. lbs.)
Spring U-bolt/Stud Nut 122 N m (90 ft. lbs.)
Spring Front Pivot Bolt . 142 N-m (105 ft. lbs.)
Spring Rear Shackle Bolt 129 N-m (95 ft. lbs.)
Track Bar to Axle Nut 168 N-m (125 ft. lbs.) J9303-33
Track Bar to Frame Bolt 168 N-m (125 ft. lbs.)
Wheel Lug Nut Vi x 20 with
60° Cone 109 to 150 N-m
(80 to 110 ft. lbs.)
J9303-31
J BRAKES 5 - 1
BRAKES
page page
A B S COMPONENT S E R V I C E 56 DISC B R A K E S 24
ANTILOCK B R A K E D I A G N O S I S 7 DRUM BRAKES 37
ANTILOCK B R A K E S Y S T E M ( A B S ) 47 GENERAL INFORMATION 1
ANTILOCK B R A K E S Y S T E M O P E R A T I O N . . . . 52 PARKING B R A K E S 40
BRAKE A D J U S T M E N T S - F L U I D L E V E L - SPECIFICATIONS 65
BLEEDING 11 S T A N D A R D B R A K E DIAGNOSIS 3
B R A K E P E D A L AND S W I T C H 45 STANDARD M A S T E R CYLINDER 18
B R A K E L I N E S AND VALVES 20 STANDARD POWER BRAKE BOOSTER 16
GENERAL INFORMATION
INDEX
page page
Antilock Brake System (ABS) 1 Brakelining Material . 1
Brake Fluid/Lubricants/Cleaning Solvents 2 Hydraulic Components 1
Brake Safety Precautions 2 Jeep Body Code Letters . . . . . . . . . . . . . . . . . . . . 2
Brake Specifications 2 Power Brakes 1
Brake Warning Lights 1 Wheel Brake Components 1
W H E E L BRAKE COMPONENTS BRAKELINING MATERIAL

Front disc and rear drum brakes are used on all The factory installed brakelining on all models con
models. The disc brake components consist of single sists of an organic base material combined with me
piston calipers and ventilated rotors. The drum tallic particles. The lining does not contain asbestos.
brakes are dual shoe, internal expanding units with
cast brake drums and wheel cylinders. BRAKE WARNING LIGHTS
The parking brake mechanism is cable operated. A red, brake warning light is used to alert the
The cables are attached to operating levers connected driver if a pressure differential exists between the
to the rear brake trailing shoes. The cables are oper front and rear hydraulic systems. The light also
ated by a foot pedal assembly on YJ models. A hand alerts the driver when the parking brakes are ap
lever assembly is used on XJ models. plied. The light illuminates for a few seconds at start
up as part of a bulb check procedure.
POWER BRAKES An additional warning light is used on models with
Power brakes are standard on all models. A vac antilock brakes. This light is amber in color and is
uum operated power booster is used for standard and located in the same side of the instrument cluster as
ABS brake applications. the red warning light. The amber light illuminates
only when an antilock system fault occurs.
HYDRAULIC COMPONENTS
A dual reservoir master cylinder is used for all ANTILOCK B R A K E S Y S T E M (ABS)
standard brake applications. A combination propor An antilock brake system (ABS) is available on
tioning valve/pressure differential switch is used. A XJ/YJ models. The system is an electronically oper
center feed style master cylinder is used for ABS ated, all-wheel brake control system. The ABS sys
brake applications. tem is designed to retard wheel lockup during
periods of high wheel slip braking. Refer to the anti-
lock brake section for operation and service informa
tion.
5 - 2 BRAKES J
BRAKE SPECIFICATIONS • Code letters YJ: Wrangler/YJ
Brake torque specifications are provided at the end The code letters are used throughout this group to
of this group. simplify model identification and component applica
tion.
BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Recommended fluid for all Jeep vehicles is Mopar BRAKE SAFETY PRECAUTIONS
DOT 3 brake fluid, or an equivalent meeting SAE
J1703 and DOT 3 standards. WARNING: ALTHOUGH FACTORY INSTALLED
Use Mopar Multi Mileage grease to lubricate cali B R A K E L I N I N G ON J E E P V E H I C L E S I S MADE FROM
per slide surfaces, drum brake pivot pins and rear A S B E S T O S F R E E M A T E R I A L S , S O M E A F T E R MAR
brakeshoe contact points on the support plates. Use K E T B R A K E L I N I N G MAY CONTAIN A S B E S T O S .
GE 661 or Dow 111 silicone grease on caliper bush T H I S S H O U L D B E T A K E N INTO ACCOUNT W H E N
SERVICING A V E H I C L E W I T H P R I O R B R A K E S E R
ings and mounting bolts.
VICE. W E A R A R E S P I R A T O R W H E N CLEANING
Use fresh brake fluid or Mopar brake cleaner to
B R A K E C O M P O N E N T S A S A S B E S T O S F I B E R S CAN
clean or flush brake system components. These are
B E A H E A L T H HAZARD. NEVER CLEAN W H E E L
the only cleaning materials recommended.
B R A K E COMPONENTS W I T H C O M P R E S S E D A I R .
CAUTION: Never use gasoline, kerosene, alcohol, U S E A VACUUM C L E A N E R S P E C I F I C A L L Y D E
motor oil, transmission fluid, or any fluid containing S I G N E D F O R REMOVING B R A K E D U S T . I F A VAC
mineral oil to clean the system components. These UUM C L E A N E R I S N O T A V A I L A B L E , C L E A N T H E
fluids damage rubber cups and seals. If system P A R T S W I T H W A T E R D A M P E N E D S H O P R A G S . DO
contamination i s suspected, check the fluid for dirt, NOT C R E A T E D U S T B Y SANDING B R A K E L I N I N G .
discoloration, or separation into distinct layers. D I S P O S E O F A L L D U S T AND D I R T S U S P E C T E D O F
Drain and flush the system with new brake fluid if CONTAINING A S B E S T O S F I B E R S IN S E A L E D B A G S
OR C O N T A I N E R S . F O L L O W A L L R E C O M M E N D E D
contamination i s suspected.
S A F E T Y P R A C T I C E S P R E S C R I B E D B Y T H E OCCU
P A T I O N A L S A F E T Y AND H E A L T H ADMINISTRA
JEEP BODY CODE LETTERS TION (OSHA) AND T H E E N V I R O N M E N T A L
The body/model identification code letters for Jeep P R O T E C T I O N AGENCY (EPA), F O R HANDLING AND
vehicles are as follows: D I S P O S A L O F P R O D U C T S CONTAINING A S B E S
• Code letters XJ: Cherokee TOS.
J STANDARD BRAKE DIAGNOSIS 5 -3
STANDARD BRAKE DIAGNOSIS
INDEX
page page
Diagnosing Brake Problems 3 Power Booster Check Valve Test . 6
Diagnosis Procedures 3 Power Booster Vacuum Test 6
Master Cylinder/Power Booster Test 6
DIAGNOSIS PROCEDURES (e) If fluid separates into layers, obviously con

Brake diagnosis involves determining if a problem tains oil, or a substance other than brake fluid,
is related to a mechanical, hydraulic or vacuum op system seals and cups will have to be replaced and
erated component. A preliminary brake check, fol hydraulic system flushed.
lowed by road testing and component inspection are (4) Check parking brake operation. Verify free
needed to determine a problem cause. movement and full release of cables and foot pedal or
Road testing will either verify proper brake opera hand lever. Also note if vehicle was being operated
tion or confirm the existence of a problem. Compo with parking brake partially applied.
nent inspection will, in most cases, identify the (5) Check brake pedal operation. Verify that pedal
actual part responsible for a problem. does not bind and has adequate free play. If pedal
The first diagnosis step is the preliminary brake lacks free play, check pedal and power booster for be
check. This involves inspecting fluid level, parking ing loose or for bind condition. Do not road test until
brake action, wheel and tire condition, checking for condition is corrected.
obvious leaks or component damage and testing (6) If components checked appear OK, road test the
brake pedal response. A road test will confirm or vehicle.
deny the existence of a problem. The final diagnosis
procedure involves road test analysis and a visual in ROAD TESTING
spection of brake components. (1) If complaint involved low brake pedal, make
several low speed stops and note if the pedal comes
PRELIMINARY BRAKE CHECK back up to normal height.
(1) Check condition of tires and wheels. Damaged (2) Check brake pedal response with transmission
wheels and worn, damaged, or underinflated tires in Neutral and engine running. Pedal should remain
can cause pull, shudder, tramp and a condition simi firm under steady foot pressure.
lar to grab. (3) During road test, make normal and firm brake
(2) If complaint was based on noise when braking, stops in 25-40 mph range. Note faulty brake opera
check suspension components. Jounce front and rear tion such as pull, grab, drag, noise, low pedal, hard
of vehicle and listen for noise that might be caused pedal, fade, pedal pulsation, etc.
by loose, worn, or damaged suspension or steering (4) Inspect suspect brake components and refer to
components. problem diagnosis information for causes of various
(3) Inspect brake fluid level and condition. brake conditions.
(a) Fluid level should be within 6 mm (1/4 in.) of
reservoir rims, or to level indicator on reservoir. COMPONENT INSPECTION
(b) Check fluid condition. Fluid should be reason Fluid leak points and dragging brake units can usu
ably clear and free of foreign material. Note that ally be located without removing any components. The
brake fluid tends to darken over time. This is area around a leak point will be wet with fluid. The
normal and should not be mistaken for con components at a dragging brake unit (wheel, tire, rotor)
tamination. If the fluid is reasonably clear and will be quite warm or hot to the touch.
free of foreign material, it is OK. Other brake problem conditions will require compo
(c) Remember that fluid level in the front disc nent removal for proper inspection. Raise the vehicle
brake reservoir will decrease in proportion to nor and remove the necessary wheels for better visual ac
mal lining wear. However, if fluid level is abnor cess.
mally low, look for leaks at calipers, wheel
cylinders, brakelines and master cylinder. DIAGNOSING BRAKE PROBLEMS
(d) If fluid is highly discolored, or appears to con
tain foreign material, drain out a sample with a BRAKE WARNING LIGHT OPERATION
clean suction gun. Pour sample in a glass container The red brake warning light will illuminate under
and note condition. the following conditions:
5 - 4 STANDARD BRAKE DIAGNOSIS J
• for 2-3 seconds at startup as part of normal bulb BRAKE DRAG

check Brake drag occurs when the lining is in constant
• parking brakes applied contact with the rotor or drum. Drag can occur at
• low pedal caused by malfunction in front/rear brake one wheel, all wheels, fronts only, or rears only. It is
hydraulic circuit (differential switch valve actuated) a product of incomplete brakeshoe release. Drag can
If the red light remains on after startup, first verify be minor or severe enough to overheat the linings,
that the parking brakes are fully released. Then check rotors and drums.
pedal action and fluid level. A red light indicates that Brake drag also has a direct effect on fuel economy. If
the valve in the differential pressure switch has been undetected, minor brake drag can be misdiagnosed as
actuated. If a problem is confirmed, inspect the hydrau an engine or transmission/torque converter problem.
lic system and wheel brake components. Minor drag will usually cause slight surface charring
On models with antilock brakes (ABS), the amber of the lining. It can also generate hard spots in rotors
warning light only illuminates when an ABS compo and drums from the overheat/cool down process. In most
nent has malfunctioned. The ABS light operates inde cases, the rotors, drums, wheels and tires are quite
pendently of the red warning light. Refer to the antilock warm to the touch after the vehicle is stopped.
brake section for more detailed diagnosis information. Severe drag can char the brake lining all the way
through. It can also distort and score rotors and
PEDAL FALLS AWAY drums to the point of replacement. The wheels, tires
A brake pedal that falls away under steady foot and brake components will be extremely hot. In se
pressure is generally the result of a system leak. The vere cases, the lining may generate smoke as it chars
leak point could be at a brakeline, fitting, hose,
from overheating.
wheel cylinder, or caliper. Internal leakage in the
Some common causes of brake drag are:
master cylinder caused by worn or damaged piston
• loose or damaged wheel bearing
cups, may also be the problem cause.
If leakage is severe, fluid will be evident at or around • seized or sticking caliper or wheel cylinder piston
the leaking component. However internal leakage in • caliper binding on bushings or slide surfaces
the master cylinder will not be physically evident. Refer • loose caliper mounting bracket
to the cylinder test procedure in this section. • distorted brake drum or shoes
• rear brakeshoes binding on worn/damaged support
LOW PEDAL plates
If a low pedal is experienced, pump the pedal sev • misassembled components.
eral times. If the pedal comes back up, worn lining If brake drag occurs at all wheels, the problem may
and worn rotors or drums are the most likely causes. be related to a blocked master cylinder compensator
However, if the pedal remains low and/or the warn port or faulty power booster (binds-does not release).
ing light illuminates, the problem is in the master The brakelight switch can also be a cause of drag.
cylinder, wheel cylinders, or calipers. An improperly mounted or adjusted brakelight
A decrease in master cylinder fluid level may only switch can prevent full brake pedal return. The re
be the result of normal lining wear. Fluid level will sult will be the same as if the master cylinder com
decrease in proportion to normal wear. It is a result pensator ports are blocked. The brakes would be
of the outward movement of caliper and wheel cylin partially applied causing drag.
der pistons to compensate for normal wear. Top off
reservoir fluid level and check brake operation to BRAKE FADE
verify a problem. Brake fade is a product of overheating caused by
brake drag. However, overheating and subsequent fade
SPONGY PEDAL
can also be caused by riding the brake pedal, making
A spongy pedal is most often caused by air in the
repeated high deceleration stops in a short time span, or
system. However, thin drums or substandard brake
lines and hoses will also cause a condition similar to constant braking on steep roads. Refer to the Brake
a spongy pedal. The proper course of action is to Drag information in this section for causes.
bleed the system, or replace thin drums and suspect
PEDAL PULSATION
quality brake lines and hoses.
Pedal pulsation is caused by components that are
HARD PEDAL OR HIGH PEDAL EFFORT loose, or beyond tolerance limits.
A hard pedal or high pedal effort may be due to Disc brake rotors with excessive lateral runout or
lining that is water soaked, contaminated, glazed, or thickness variation, or out of round brake drums are
badly worn. The power booster or check valve could the primary causes of pulsation. Other causes are loose
also be faulty. Test the booster and valve as de wheel bearings or calipers and worn, damaged tires.
scribed in this section.
J S T A N D A R D B R A K E DIAGNOSIS 5 - I
PULL seals replaced. Foreign material lodged in the reser

A front pull condition could be the result of: voir compensator/return ports can cause brake drag
• contaminated lining in one caliper by restricting fluid return after brake application.
• seized caliper piston Brake fluid contaminated by a non-recommended
• binding caliper fluid will usually be discolored, milky, oily looking, or
• loose caliper foamy. In some cases, it may even appear as if the fluid
• loose or corroded slide pins contains sludge. However, remember that brake
• improper brakeshoes fluid will darken in time and occasionally be
• damaged rotor cloudy in appearance. These are normal conditions
• incorrect wheel bearing adjustment (at one wheel) and should not be mistaken for contamination.
A worn, damaged wheel bearing or suspension If some type of oil has been added to the system,
component are further causes of pull. A damaged the fluid will separate into distinct layers. To verify
front tire (bruised, ply separation) can also cause this, drain off a sample with a clean suction gun.
pull. Then pour the sample into a glass container and ob
A common and frequently misdiagnosed pull condi serve fluid action. If the fluid separates into distinct
tion is where direction of pull changes after a few
layers, it is definitely contaminated.
stops. The cause is a combination of brake drag fol
The only real correction for contamination by non-
lowed by fade at the dragging brake unit.
recommended fluid is to flush the entire hydraulic
As the dragging brake overheats, efficiency is so
reduced that fade occurs. If the opposite brake unit is system and replace all the seals.
still functioning normally, its braking effect is mag BRAKE NOISE
nified. This causes pull to switch direction in favor of
the brake unit that is functioning normally. Squeak/Squeal
When diagnosing a change in pull condition, re Brake squeak or squeal may be due to linings that
member that pull will return to the original direction are wet or contaminated with brake fluid, grease, or oil.
if the dragging brake unit is allowed to cool down Glazed linings and rotors with hard spots can also con
(and is not seriously damaged). tribute to squeak. Dirt and foreign material embedded
REAR BRAKE GRAB in the brake lining will also cause squeak/squeal.
Rear grab (or pull) is usually caused by contaminated A very loud squeak or squeal is frequently a sign of
lining, bent or binding shoes and support plates, or im severely worn brake lining. If the lining has worn
properly assembled components. This is particularly through to the brakeshoes in spots, metal-to-metal con
true when only one rear wheel is involved. However, tact occurs. If the condition is allowed to continue, ro
when both rear wheels are affected, the master cylinder tors can become so scored that replacement is necessary.
or proportioning valve could be at fault.
Thump/Clunk
BRAKES DO NOT HOLD AFTER DRIVING Thumping or clunk noises during braking are fre
THROUGH DEEP WATER PUDDLES quently not caused by brake components. In many
This condition is generally caused by water soaked cases, such noises are caused by loose or damaged
lining. If the lining is only wet, it can be dried by steering, suspension, or engine components. How
driving with the brakes lightly applied for a mile or ever, calipers that bind on the slide surfaces can gen
two. However, if the lining is both wet and dirty, dis erate a thump or clunk noise. In addition, worn out,
assembly and cleaning will be necessary. improperly adjusted, or improperly assembled rear
BRAKE FLUID CONTAMINATION brakeshoes can also produce a thump noise.
There are two basic causes of brake fluid contamina Chatter
tion. The first involves allowing dirt, debris, or other
Brake chatter is usually caused by loose or worn
liquid materials to enter the cylinder reservoirs when
the cover is off. The second involves adding to, or filling components, or glazed/burnt lining. Rotors with hard
the cylinder reservoirs with a non-recommended fluid. spots can also contribute to chatter. Additional
Brake fluid contaminated with only dirt, or debris causes of chatter are out of tolerance rotors, brake
usually retains a normal appearance. In some cases, lining not securely attached to the shoes, loose wheel
the foreign material will remain suspended in the bearings and contaminated brake lining.
fluid and be visible. The fluid and foreign material BRAKELINING CONTAMINATION
can be removed from the reservoir with a suction
Brakelining contamination is usually a product of
gun but only if the brakes have not been applied. If
leaking calipers or wheel cylinders, driving through
the brakes are applied after contamination, system
deep water puddles, or lining that has become cov
flushing will be required. The master cylinder may
ered with grease and grit during repair.
also have to be disassembled, cleaned and the piston
6 - 6 STANDARD BRAKE DIAGNOSIS J
WHEEL AND TIRE PROBLEMS BOOSTER

Some conditions attributed to brake components CHECK
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can
produce a condition similar to grab as the tire loses
and recovers traction.
Flat-spotted tires can cause vibration and wheel
tramp and generate shudder during brake operation.
A tire with internal damage such as a severe
bruise or ply separation can cause pull and vibration.
MASTER CYLINDER/POWER BOOSTER TEST

(1) Start engine and check booster vacuum hose
connections. Hissing noise indicates vacuum leak. Fig. 1 Vacuum Check Valve And Seal (Typical)
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neutral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure.
(a) If pedal holds firm, proceed to step (5).
(b) If pedal does not hold firm and falls away,
master cylinder is faulty (internal leakage). Over
haul or replace cylinder. J9005-80
(5) Start engine and note pedal action. Fig. 2 Hand Operated Vacuum Pump (Typical)
(a) If pedal falls away slightly under light foot
pressure then holds firm, proceed to. step (6). (3) Clamp hose shut between vacuum source and
(b) If no pedal action is discernible, power booster check valve (Fig. 3).
or vacuum check valve is faulty. Install known good (4) Stop engine and observe vacuum gauge.
check valve and repeat steps (2) through (5). (5) If vacuum drops more than one inch HG (33
(6) Rebuild booster vacuum reserve as follows: Re millibars) within 15 seconds, booster diaphragm or
lease brake pedal. Increase engine speed to 1500 check valve is faulty.
rpm, close throttle and immediately turn off ignition.
SHORT
(7) Wait a minimum of 90 seconds and try brake CONNECTING CHECK
action again. Booster should provide two or more
vacuum assisted pedal applications. If vacuum assist
is not provided, perform booster and check valve vac
uum tests.
POWER BOOSTER CHECK WALWE TEST

(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster (Fig. 1).
(3) Hand operated vacuum pump can be used for
test (Fig. 2).
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 1).
(5) Vacuum should hold steady. If gauge on pump
indicates any vacuum loss, valve is faulty and must
be replaced.
VACUUM
POWER BOOSTER VACUUM TEST GAUGE
(1) Connect a vacuum gauge to the booster check
J9005-81
valve with a short length of hose and T-fitting (Fig. 3).
(2) Start and run engine at idle speed for one Fig. 3 Booster Vacuum Test Connections
minute.
J ANTILOCK BRAKE DIAGNOSIS 5-7
ANTILOCK BRAKE DIAGNOSIS
INDEX
page page
A B S Fault Diagnosis 8 Loss of Sensor Input 7
A B S System Wiring and Electrical Circuits 8 Operating Sound Levels 7
A B S Warning Light Display 7 Rear Speed Sensor Air Gap 7
Brake Warning Light Display 8 Steering Response 7
Diagnosis Procedures 7 Vehicle Response in Antilock Mode . 7
E C U Diagnosis 8
Wheel/Tire Size and Input Signals 7
HCU Diagnosis 8
DIAGNOSIS PROCEDURES condition and should not be mistaken for faulty oper
ABS diagnosis involves three basic steps. First is ation. However, under most conditions, pump and so
observation of the warning light display. Second is a lenoid valve operating sounds should not be audible.
visual examination for low fluid level, leaks, parking
brakes applied, or obvious damage to system compo VEHICLE RESPONSE IN ANTILOCK MODE
nents or wires. The third step involves using the During antilock braking, the HCU solenoid valves
DRB II scan tool to identify a faulty component. cycle rapidly in response to ECU inputs.
The visual examination requires a check of reser The driver will experience a slight pulsing sensa
voir fluid level and all system components. Things to tion within the vehicle as the solenoids decrease,
look for are leaks, loose connections, or obvious com hold, or increase pressure as needed. A pulsing brake
ponent damage. pedal will also be noted.
The final diagnosis step involves using the DRB II The pulsing sensation occurs as the solenoids cycle
scan tool to determine the specific circuit or compo during antilock mode braking. A slight pulse in the
nent at fault. The tester is connected to the ABS di brake pedal may also be noted during the dynamic
agnostic connector in the passenger compartment. self check part of system initialization.
The connector is at the driver side of the center con
sole under the instrument panel. Refer to the DRB II STEERING RESPONSE
scan tool Manual for tester procedures. Also refer to A modest amount of steering input is required dur
the ABS Fault Diagnosis charts at the end of this ing extremely high deceleration braking, or when
section for additional diagnosis information. braking on differing traction surfaces. An example of
Initial faults should be cleared and the vehicle road differing traction surfaces would be when the left
tested to reset any faults that remain in the system. side wheels are on ice and the right side wheels are
Faults can be cleared with the DRB II scan tool. on dry pavement.
REAR SPEED SENSOR AIR GAP L O S S OF S E N S O R I N P U T

The front wheel sensors are fixed and cannot be ad Sensor malfunctions will most likely be due to
justed. Only the rear sensor air gap is adjustable. Air loose connections, damaged sensor wires, incorrect
gap must be set with a brass feeler gauge. rear sensor air gap, or a malfunctioning sensor. Ad
Correct air gap is important to proper signal gen ditional causes of sensor faults would be sensor and
eration. An air gap that is too large may cause com tone ring misalignment or damage.
plete loss of sensor input. Or, a gap that is too small
could produce a false input signal, or damaging con ABS WARNING LIGHT DISPLAY
tact between the sensor and tone ring.
ABS Light Illuminates At Startup
WHEEL/TIRE SIZE AND INPUT SIGNALS The amber ABS light illuminates at startup as
Antilock system operation is dependant on accurate part of the system self check feature. The light illu
signals from the wheel speed sensors. Ideally, the ve minates for 2-3 seconds then goes off as part of the
hicle wheels and tires should all be the same size normal self check routine.
and type. However, the Jeep ABS system is designed
ABS Light Remains On After Startup
to function with a compact spare tire installed.
An ABS system fault is indicated when the light
OPERATING SOUND L E V E L S remains on after startup. Diagnosis with the DRB II
The ABS pump and solenoid valves may produce scan tool will be necessary to determine which ABS
some sound as they cycle on and off. This is a normal component has malfunctioned.
5 - 8 ANTILOCK BRAKE DIAGNOSIS : J
ABS Light Illuminates During Brake Stop HCU DIAGNOSIS

A system fault such as loss of speed sensor signal The HCU pump and motor and solenoid valve body
or solenoid failure, will cause the amber warning are serviced only as an assembly. The HCU assembly
light to illuminate. The most effective procedure here should not be replaced unless a fault has actually
is to check for obvious damage first. Then check the been confirmed. Verify fault conditions with the DRB
electronic components with the DRB II scan tool. II scan tool before proceeding with repair.
BRAKE WARNING LIGHT DISPLAY ABS SYSTEM WIRING AND ELECTRICAL CIRCUITS
The red brake warning light and the ABS light op Location of the ABS fuse (in the fuse panel) is
shown in Figure 15. The engine compartment har
erate independently. If the red light remains on after
ness routing for the ABS components is shown in
startup or illuminates during a brake stop, refer to
Figures 1 and 2.
the standard brake system diagnosis section. Either
the parking brakes are applied, or a wheel brake ABS FAULT DIAGNOSIS
malfunction has occurred. The fault diagnosis chart provides additional infor
mation on potential ABS system faults. Use the
ECU DIAGNOSIS chart as a guide when diagnosing a system problem.
The ECU controls all phases of antilock system op
eration. It also differentiates between normal and an
tilock mode braking.
The ECU monitors and processes the signals gen
erated from all of the system sensors at all times.
ECU circuitry and electrical connections are shown
in Figure 15.
The ECU program includes a self check routine
that tests each of the system components. The self
check occurs during both phases of the initialization
program. A failure of the self check program will
cause the immediate illumination of the amber warn
ing light. The light will also illuminate if a solenoid
or other system component fails during the dynamic
phase of initialization.
If a system malfunction should occur, do not imme
diately replace the ECU. A blown system fuse, bad
chassis ground, or loss of feed voltage will each cause
a system malfunction similar to an ECU failure.
Never replace the ECU unless diagnosis with the
DRB II scan tool indicates this is necessary.
J9205-16
Fig. 1 ABS Fuse Location

ANTILOCK BRAKE DIAGNOSIS i - 9
HEADLAMP HEADLAMP
AND DASH A N D DASH
HARNESS HARNESS
BODY
WITH GROUNDS
STANDARD
BRAKES
POWER
DISTRIBUTION
CENTER
RELAY
(BY PASS)
DIFFERENTIAL
PRESSURE
PEDAL SWITCH HARNESS
TRAVEL PEDAL
SENSOR TRAVEL
SENSOR COMBINATION
HARNESS VALVE J9205-31
Fig. 2 ABS Engine Compartment Harness Routing (XJ)

5 - 1 0 A N T I L O C K B R A K E DIAGNOSIS
ABS FAULT DIAGNOSIS
ABS CONDITION PROBABLE CAUSE ABS CONDITION PROBABLE CAUSE
W H E E L S E N S O R FAULT 1. Sensor disconnected. INADEQUATE FEED 1 . Battery discharged o r low on

2 . Incorrect sensor a i r gap (usually VOLTAGE (NOT charge.
too large). ENOUGH VOLTAGE 2 . Battery cables loose o r corroded
3. Damaged sensor wire. T O OPERATE SYSTEM) {at terminals).
4. Damaged sensor o r tone ring. 3. Loose, corroded system ground.
5 . Sensor a n d / o r tone ring loose o r 4. Loose harness connections o r
misaligned. corroded connections.
HCU SOLENOID VALVE 1 . Bad E C U . DECREASING BRAKE Noticeable decrease during A B S

FAULT 2. H C U wire harness short, open P E D A L H E I G H T ( M O V E S stops is due to:
loose connection, o r w i r e damage. CLOSER T O FLOOR) (a) Fluid leak,
3. System circuit breakers (in PDC) b) A i r in system.
faulty. (c) Pedal travel sensor cap and
4. Relay fault. booster are mismatched.
(d) Pedal travel sensor o r pump
PUMP M O T O R FAULT 1. Fuse o r wire harness problem. malfunction.
2. Relay malfunction.
3. Pump motor sensor malfunction. INCREASING BRAKE 1. Pump motor wire harness problem
4. Pedal travel sensor fault (short, PEDAL HEIGHT, PUMP (short, open, ground, loose,
open, mismatched). RUNS CONTINUOUSLY damaged).
5 . Pump motor malfunction. DURING ABS STOP 2. Pedal travel sensor fault.
(PEDAL F A R T H E R
M A I N RELAY FAULT 1 . Short o r open in relay. F R O M FLOOR)
2 . Short o r open in relay w i r i n g .
3. Inadequate feed voltage (less than ACCELERATION 1. Switch wires loose, damaged.
9 volts). SWITCH FAULT 2 . Switch malfunction.
A B S LIGHT O N B U T N O 1 . A B S fuse blown. 3. Switch mounted upside down.
FAULT CODE SET 2 . Inadequate feed voltage to E C U
(less than 9 volts).
3. E C U ground wire damage o r loose
connection.
4. M a i n relay inoperative.
J9205-38
J BRAKE ADJUSTMENTS—FLUID LEWEL—BLEEDING i - 11
BRAKE ADJUSTMENTS—FLUID LEVEL—BLEEDING
INDEX
page page
Brake Bleeding-XJ/YJ with A B S Brakes 14 Parking Brake Adjustment—XJ 11
Brake Bleeding—XJ/YJ with Standard Brakes . . . 13 Parking Brake Adjustment—YJ 12
Brake Fluid Contamination . . . . . . . . . . . . . . . . . . 13 Rear Drum Brake Adjustment 11
Brake Fluid Level 13 Recommended Brake Fluid 12
Brakelight Switch Adjustment 15 Wheel Nut Tightening 12
REAR DRUM BRAKE ADJUSTMENT (7) Repeat adjustment at opposite brakeshoe as-
The rear drum brakes are equipped with a self ad BRAKE SHOES
justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
The only tool needed for adjustment is a standard
brake gauge.
Adjustment is performed with the brakeshoes in
stalled on the support plate. Procedure is as follows:
ADJUSTMENT PROCEDURE
(1) Raise and support vehicle rear end and remove
wheels and brake drums.
(2) Verify that left/right automatic adjuster lever
and cable are properly connected.
(3) Insert brake gauge in drum. Expand gauge un
til gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 1). Fig. 2 Adjusting Brakeshoes To Gauge
sembly.
(8) Install brake drums and wheels and lower ve
hicle.
(9) Make final adjustment as follows: Drive vehicle
and make one forward stop followed by one reverse
stop. Repeat procedure 8-10 times to actuate self ad
juster components and equalize adjustment. Bring
vehicle to complete standstill at each stop. Incom
plete, rolling stops will not activate adjuster mecha
nism.
PARKING BRAKE A D J U S T M E N T - X J
(1) Adjust rear brakes. Refer to procedure in this
section.
(2) Fully apply and release parking brake hand le
ver four or five times.
Fig. 1 Adjusting Gauge To Brake Drum (3) Place hand lever in fifth notch.
(4) Raise vehicle.
(4) Reverse gauge and install it on brakeshoes
(5) Loosen equalizer locknut (Fig. 3).
(Fig. 2). Position gauge legs at shoe centers as
(6) Install Parking Brake Adjustment Gauge 7914
shown. If gauge does not fit (too loose or tight), ad
just shoes. on an inch-pound torque wrench (Fig. 4).
(5) Pull shoe adjuster star wheel away from ad (7) Position adjustment gauge on one rear cable
juster lever. (Fig. 3).
(6) Turn adjuster star wheel (by hand) to expand (8) Apply and hold torque of 5-6 N*m (45-50 in.
or retract brakeshoes. Continue adjustment until lbs.) on adjustment gauge and note position of gauge
gauge outside legs are light drag-fit on shoes (Fig. 2). pointer.
5 - 12 BRAKE ADJUSTMENTS—FLUID LEVEL—BLEEDING J
(2) Fully apply parking brakes.
(3) Raise vehicle.
(4) Loosen front cable locknut (Fig. 5).
(5) Tighten front cable adjusting nut approxi
mately 13 mm (1/2 in.). This will apply necessary
force to front cable tensioner.
(6) Hold cable adjusting nut in position and
tighten cable locknut.
(7) Lower vehicle until rear wheels are about
15-20 cm (6-8 in.) off shop floor.
(8) Release parking brake pedal and verify that
rear wheels rotate freely without drag.
REAR LOCKNUT ADJUSTING EQUALIZER FRONT
Fig. 3 Parking Brake Components—XJ

(9) If adjustment gauge pointer is not in O K band,
turn equalizer locknut in or out until pointer is
within OK band.
J9105-22
Fig. 5 Parking Brake Equalizer And Cables—YJ

WHEEL NUT TIGHTENING
The wheel attaching nuts must be tightened prop
erly to ensure efficient brake operation. Overtighten
ing the nuts or tightening them in the wrong
sequence can cause distortion of the brake rotors and
drums.
Impact wrenches are not recommended for tighten
ing wheel nuts. A torque wrench should be used for
this purpose.
The correct tightening sequence is important in
avoiding rotor and drum distortion. The correct se
quence is in a diagonal crossing pattern (Fig. 6).
Seat the wheel and install the wheel nuts finger
tight. Tighten the nuts in the sequence to half the
required torque. Then repeat the tightening sequence
to final specified torque.
RECOMMENDED BRAKE FLUID

Fig. 4 Checking Cable Adjustment—XJ The only brake fluid recommended for Jeep vehi
(10) Remove tools and lower vehicle. cles with standard or antilock brakes is Mopar brake
(11) Apply and release parking brakes four or five fluid, or an equivalent fluid meeting SAE J1703 and
times and check adjustment again. Readjust cable if DOT 3 standards.
drag is noted. Use new brake fluid only to top off the master
cylinder or refill the system. Never use re
PARKING BRAKE ADJUSTMENT-YJ claimed fluid, fluid not meeting the SAE/DOT
(1) Adjust rear brakeshoes to drum if necessary. standards or fluid from an unsealed container.
Refer to procedure in this section. Do not use fluid from any container that has
J BRAKE A D J U S T M E N T S — F L U I D L E V E L — B L E E D I N G i - 13
On standard brake models, bleeding can be per

formed either manually or with pressure equipment.
However, if pressure equipment is used, it will be
necessary to hold the front brake metering valve
open in order to bleed the front brakes. The valve
can be held open with a tension clip tool or by hand.
It will also be necessary that a suitable size pressure
tank hose adapter be available for use on the master
cylinder.
MANUAL BLEEDING PROCEDURE

(1) If master cylinder has been overhauled or a
new cylinder will be installed, bleed cylinder on
bench before installation. This shortens time needed
to bleed system and ensures proper cylinder opera
tion.
(2) Wipe master cylinder reservoir and cap clean
with shop towels.
(3) Remove cover and fill master cylinder reservoir
with Mopar, or equivalent DOT 3 brake fluid.
J8905-15 (4) Open all caliper and wheel cylinder bleed
screws.
Fig. 6 Wheel Nut Tightening Sequence (5) Close bleed screws after fluid begins flowing
been left open for any length of time. Fluid in from each bleed screw.
open containers can absorb moisture. (6) Top off master cylinder reservoir again.
(7) Use following bleed sequence:
BRAKE FLUID LEVEL • master cylinder
Always clean the master cylinder and cover before • right rear
checking fluid level. If not cleaned, dirt from the • left rear
cover could enter the fluid. Also check the cover seal • right front
and replace it if torn or distorted. • left front
Correct fluid level is to within 6 mm (1/4 in.) of (8) Observe following brake bleeding precautions:
reservoir rim, or to the fill mark on the models with • Do not pump brake pedal at any time while bleed
a plastic reservoir. Refer to the Antilock Brake sec ing. Air in system will be compressed into small bub
tion for fluid levels on models equipped with ABS bles that are distributed throughout hydraulic
brakes. system. This will make a second and third bleeding
operation necessary.
BRAKE FLUID CONTAMINATION • Bleed only one wheel brake unit at a time and use
Oil in the fluid will cause brake system rubber a bleed hose to bleed each wheel brake unit (Fig. 7).
seals to soften and swell. The seals may also become • Attach one end of bleed hose to bleed screw and in
porous and begin to deteriorate. sert opposite end in glass container partially filled
If fluid contamination is suspected, drain off a sam with brake fluid (Fig. 7). Glass container makes it
ple from the master cylinder. A suction gun or simi easier to see air bubbles as they exit the bleed hose.
lar device can be used for this purpose. • Be sure end of bleed hose is immersed in fluid. Im
Empty the drained fluid into a glass container. mersing hose end in fluid prevents air from being
Contaminants in the fluid will cause the fluid to sep drawn back into cylinder and brakeline.
arate into distinct layers. If contamination has oc (9) Bleed master cylinder first. Have helper oper
curred, the system rubber seals, hoses and cups must ate brake pedal while bleeding each master cylinder
be replaced and the system thoroughly flushed with fluid outlet line.
clean brake fluid.
CAUTION: Do not allow the master cylinder to run
BRAKE BLEEDING-XJ/YJ WITH STANDARD out of fluid when bleeding the brakes. An empty
cylinder will allow additional air to be drawn into
BRAKES
the system. Check the cylinder fluid level frequently
Use Mopar DOT 3 brake fluid, or an equivalent
and add fluid as needed.
meeting SAE/DOT standards J1703-F and DOT 3, to
fill and bleed the system. (10) Bleed each wheel brake unit as follows:
S - 14 BRAKE ADJUSTMENTS—FLUID LEVEL—BLEEDING 4
(6) Bleed master cylinder first. Then bleed rear

brakes as described in manual bleeding procedure.
(7) Bleed front brakes as described in manual
bleeding procedure. Have helper hold metering valve
open by pressing valve stem inward slightly. Amount
of valve stem movement needed to hold valve open is
quite modest. Do not use excessive force.
(8) Remove pressure bleeding equipment and top
off master cylinder reservoir.
BRAKE BLEEDING-XJ/YJ WITH ABS BRAKES

A different bleeding method is required for the
ABS system. It is basically a three step process
consisting of: A conventional manual brake
bleed. A second bleed using the DRB I I , fol
lowed by a repeat of the conventional manual
bleed procedure. Recommended ABS bleeding
procedure is as follows:
J8905-18 (1) Clean master cylinder reservoir caps and reser
voir exterior. Dirt, foreign material on the caps and
Fig. 7 Typical Bleed Hose And Fluid Container reservoir must not be allowed to enter reservoir.
(a) Open caliper or wheel cylinder bleed fitting (2) Fill reservoir with Mopar brake fluid, or equiv
1/2 to 3/4 turn. alent quality fluid meeting SAE 1703 and DOT 3
(b) Have helper press and hold brake pedal to standards.
floor. Do not pump brake pedal while bleeding. (3) Recommended bleeding sequence is:
Air in system will be compressed into small • master cylinder
bubbles that are distributed throughout hy • HCU valve body (at fluid lines)
draulic system. This will make a second and • right rear wheel
third bleeding operation necessary. • left rear wheel
(c) Tighten bleed fitting and have helper release • right front wheel
brake pedal. Continue bleeding operation until • left front wheel.
fluid entering bleed container is clear and free of (4) Attach bleed hose to caliper or wheel cylinder
bubbles. bleed fitting. Immerse end of bleed hose in glass con
(d) Repeat bleeding operation at remaining tainer partially filled with brake fluid. Be sure hose
wheel brake units. end is submerged in fluid (Fig. 7).
(e) Discard fluid bled into glass container. It (5) Bleed each wheel brake unit as follows:
should not be reused. (a) Have helper apply and hold brake pedal.
(11) Check and adjust master cylinder fluid level. (b) Open bleed screw 1/2 turn. Close bleed screw
(12) Verify proper brake operation before moving when brake pedal contacts floorpan. Do not pump
vehicle. brake pedal at any time while bleeding. This
compresses air into small bubbles which are
PRESSURE BLEEDING distributed throughout system. Additional
The front brake metering valve is located in the bleeding operations will then be necessary to
forward end of the combination valve. The valve remove all trapped air from the system.
stem is accessible from the same end of the valve. (c) Repeat bleeding operation 5-7 more times at
The stem must be either pressed inward, or held out each rear wheel brake unit.
ward slightly in order to bleed the front brakes. (d) Continue bleeding until fluid entering glass
(1) Fill bleeder tank if necessary. container is free of air bubbles. Check reservoir
(2) Purge air from bleeder tank and lines before fluid level frequently and add fluid if necessary.
proceeding. (e) Repeat bleeding procedures at front wheels.
(3) Wipe master cylinder cover clean. -j
(4) Remove master cylinder cover and install pres CAUTION: Do not allow the master c y l i n d e r reser
sure hose adapter in place of cover. A suitable voir to run dry while bleeding the brakes. Running
adapter will usually be available from tank manufac dry will allow air to re-enter the system making a
turer. second bleeding operation necessary.
(5) Connect bleeder tank pressure hose to adapter.
4 BRAKE ADJUSTMENTS—FLUID LEVEL—BLEEDING i - 15
(6) Perform "Bleed Brake" procedure with DRB II PEDAL

scan tool. Procedure is described in DRB II software S U P P O R T BRACKET
information and diagnostic manual.
(a) Connect DRB II scan tool to diagnostic con
nector.
(b) Run Bleed Brake procedure as described in
tester manual.
(7) Repeat conventional bleeding procedure out
lined in steps (1) through (8).
(8) Top off master cylinder fluid level if necessary.
(9) Verify proper brake operation.
S W I T C H CONNECTOR
BRAKELIGHT SWITCH ADJUSTMENT AND HARNESS
A plunger-type brakelight switch is used on XJ
and YJ models (Fig. 8). The switch plunger is actu BRAKELIGHT S W I T C H J91G5-23
ated directly by the brake pedal.
The switch internal contacts are open when the Fig. 8 Brakelight Switch
brake pedal is in the released position. Brake appli (a) If switch-to-pedal clearance is OK and brake-
cation moves the pedal away from the switch allow lights operate correctly, adjustment is not required.
ing the plunger to extend. As the plunger extends, (b) If switch plunger does not fully extend and
the switch internal contacts close completing the cir
clearance between pedal and switch barrel is insuf
cuit to the brakelights.
ficient, adjust switch position as described in step
A circular, metal clip is used to secure the switch
(2).
to the bracket on the pedal support. The clip has
tangs that seat in the threads of the switch plunger (2) Grasp brake pedal and pull it rearward as far
barrel. as possible. Switch plunger barrel will "ratchet" rear
ward in retaining clip to correct position.
SWITCH ADJUSTMENT PROCEDURE (3) Verify brakelight switch operation and proper
(1) Check switch adjustment. Move the brake clearance between switch plunger and brake pedal.
pedal forward by hand and note operation of the
switch plunger. Plunger should be fully extended CAUTION: B e very s u r e t h e b r a k e p e d a l returns to a
when pedal free play is taken up and brake applica fully released position after adjustment. The switch
tion begins. A clearance of approximately 3 mm (1/8 can interfere with full pedal return if too far forward.
in.) should exist between plunger and pedal at this T h e result will b e b r a k e d r a g c a u s e d by partial
point. brake application.
5-16 STANDARD POWER BRAKE BOOSTER
STANDARD POWER BRAKE BOOSTER

J
INDEX
page page
Power Brake Booster Installation 17 Service Information . . 16
Power Brake Booster Removal . . . . . . . . . . . . . . 16
SERVICE INFORMATION
The vacuum operated power brake booster is not a
serviceable component. If a booster malfunction oc
curs, the booster must be replaced as an assembly. MASTER
The booster (Figs. 1 and 2), is attached to the dash CYLINDER
panel and pedal support. ATTACHING
NUTS
CHECK
VALVE
PUSH
ROD
J9105-27 J8905-21
Fig. 1 Power Brake Booster—XJ Fig. 3 Master Cylinder Attachment (Typical)

BRAKE BRAKE
PEDAL PEDAL
(MAN. TRANS.) (AUTO. TRANS.)
P U S H ROD
BOOSTER
PUSH
MOUNTING
ROD
NUTS
BOOSTER PUSH PUSH
MOUNTING ROD ROD
BOLTS RETAINING RETAINING
J9305-79 CLIP CLIP J9105-24
Fig. 2 Power Brake Booster- YJ Fig. 4 Booster Push Rod Attachment

POWER BRAKE BOOSTER REMOVAL (4) Remove bolts/nuts attaching booster to dash
(1) Loosen but do not remove nuts attaching mas panel.
ter cylinder to booster (Fig. 3). (5) In engine compartment, loosen vacuum hose
(2) Remove instrument panel lower trim cover. clamp and disconnect vacuum hose from booster
(3) Remove retaining clip attaching booster push check valve (Fig. 5).
rod to brake pedal (Fig. 4).
— STANDARD POWER BRAKE BOOSTER 5 - 1 7
(6) Remove master cylinder attaching nuts and re

move cylinder from mounting studs on booster.
(7) Carefully move master cylinder aside and re
move booster.
POWER BRAKE BOOSTER INSTALLATION

(1) Install check valve and grommet in booster.
Also install spacer on booster, if equipped.
(2) Position booster on dash panel and install
booster mounting bolts/nuts.
(3) Working inside vehicle, install nuts on booster
mounting studs.
(4) Attach booster push rod to brake pedal. Secure
push rod with new bolt and nuts.
(5) Tighten booster mounting bolts/stud nuts to 41
N-m (30 ft. lbs.) on XJ and 34 Nnn (25 ft. lbs.) on YJ.
(6) Tighten pedal push rod bolt inner nut to 34
N«m (25 ft. lbs.) torque. Then tighten outer locknut
to 8 N»m (75 in. lbs.) torque.
(7) Install master cylinder on booster studs.
Tighten attaching nuts to 21 N«m (15 ft. lbs.).
(8) Connect vacuum hose to booster, top off master
Fig. 5 Booster Check Valve And Hose cylinder fluid level and check brake operation.
5 - 1 8 STANDARD MASTER CYLINDER
J
STANDARD MASTER CYLINDER
M A S T E R CYLINDER REMOVAL
(1) Disconnect brake lines at master cylinder,
(2) Remove cylinder mounting nuts and remove
master cylinder.
(3) Remove cylinder cover and drain fluid.
MASTER CYLINDER INSTALLATION

(1) Bleed master cylinder on bench before installa
tion. Refer to overhaul assembly procedure in this
section for bleeding method.
(2) Install cylinder on brake booster studs and in
stall cylinder attaching nuts. Tighten nuts to 21 N»m
(15 ft. lbs.).
(3) Connect brakelines to cylinder.
(4) Fill and bleed brake system.
MASTER CYLINDER OVERHAUL Fig. 2 Removing/Installing Piston Snap Ring
CYLINDER DISASSEMBLY
(1) Remove cylinder cover and drain fluid.
(2) Examine cylinder cover seal. Discard seal if
torn or distorted.
(3) Clamp cylinder in vise (Fig. 1).
Fig. 3 Removing/Installing Primary Piston

REAR
INLET PORT
Fig. 1 Cylinder Mounted In Vise

(4) Press primary piston inward with wood dowel
or phillips screwdriver and remove snap ring (Fig. 2).
(5) Remove and discard primary piston (Fig. 3).
Piston is serviced only as an assembly. Fig. 4 Removing Secondary Piston Assembly
(6) Remove secondary piston (Fig. 4). Apply air (7) Discard secondary piston. Do not disassemble
pressure through rear outlet port to ease piston out piston as components are only serviced as assembly.
of bore. Cover small ports at bottom of rear reservoir
with towel to prevent air leakage.
J STANDARD MASTER CYLINDER 5-19
CLEANING AND INSPECTION (4) Push primary piston inward and install snap
Clean the cylinder with Mopar brake cleaning sol ring (Fig. 2).
vent or clean brake fluid. Remove cleaning residue (5) Fill master cylinder reservoirs with brake fluid.
with compressed air. (6) Fabricate and install bleed tubes in master cyl
Inspect the cylinder bore. A light discoloration of inder (Fig. 6). Be sure tube ends are submerged in
the bore surface is normal and acceptable but only if brake fluid. Tubes can be fabricated from copper tub
the surface is in good condition. ing and spare brakeline fittings.
Replace the cylinder if the bore is scored, corroded, (7) Using push rod or wooden dowel (Fig. 6), press
or pitted. Do not hone the cylinder bore in an at pistons fully into bore and allow pistons to return
tempt to restore the surface. Replace the cylin
under spring pressure. Repeat this operation until
der if the bore is corroded or if doubt exists
air bubbles cease to appear in fluid.
about cylinder bore condition.
Check the outer and inner surfaces of the cylinder (8) Remove bleed tubes. Cap outlet ports and in
for cracks or porosity, especially if wet spots were stall reservoir cover and seal.
noted on the cylinder outer surface during removal
and disassembly.
Inspect the cylinder cover, seal and retainer spring.
Replace the seal if torn or distorted and replace the
cover and spring if either part is bent or damaged in
any way.
MASTER CYLINDER ASSEMBLY

(1) Coat cylinder bore and new piston assemblies
with brake fluid.
(2) Install secondary piston in bore with push and
turn motion (Fig. 5). Do not use any tools to start
seals into bore. Tools can cut seal and scratch
bore.
Fig. 6 Master Cylinder Bleeding
Fig. 5 Installing Secondary Piston

(3) Insert primary piston in bore (Fig. 3).
5 - 20 BRAKELINES AND VALVES J
BRAKELINES AND VALVES
BRAKELINES AND HOSES BRAKELINE CHARTS
Metal brakelines and rubber brake hoses should be Brakeline charts are provided in illustration Fig
inspected periodically and replaced if damaged. ures 1 thorough 6. The illustrations show typical
Rubber brake hoses should be replaced if cut, brakeline routing, hose connections and component
cracked, swollen, or leaking. Rubber hoses must be position.
replaced. They are not repairable parts.
When installing new, or original brakelines and
hoses, lubricate the fitting threads with brake fluid
before connection.
COMBINATION A N D P R O P O R T I O N I N G V A L V E S
The standard combination valve is not a service
able part. The valve must be replaced if a malfunc
tion occurs.
MASTER
CYLINDER
RESERVOIR
HOSES
DASH (TO HCU)
RIGHT
FRONT
BRAKELINE
POWER
BRAKE
BOOSTER
H O S E FROM
COMBO. VALVE
T O HCU PRIMARY
HCU
COMBINATION
VALVE
H O S E FROM
LEFT COMBO. VALVE
® T O FRONT FRONT T O HCU SECONDARY
BRAKELINE BRAKELINE
(D T O FRONT FRONT HCU

BRAKELINE BRAKE MOUNTING
FRONT HOSE BRACKET
© T O REAR SENSOR FITTING AND
BRAKE H O S E WIRE WASHERS FITTING J9305-80
Fig. 1 Front Brakeline Routing—XJ With ABS Brakes

J BRAKELINES AND VALVES 5 - 21
HCU POWER DASH M./CYL. T O

MASTER BOOSTER COMBO. VALVE
HCU SECONDARY HOSE CYLINDER SECONDARY L I N E
PRIMARY* r
HOSE M./CYL T O
COMBO. VALVE H O S E FROM
PRIMARY L I N E COMBO. VALVE T O
HCU PRIMARY
DRIVER
SIDE
APRON
RIGHT
FRONT
BRAKELINE
(TO HOSE)
HCU T O RIGHT
F R O N T BRAKELINE
FRONT
(D HCU T O LEFT BRAKELINE
F R O N T BRAKELINE (FROM HCU)
REAR
© HCU T O R E A R BRAKELINE
BRAKELINE FITTING
(FROM HCU)
WASHERS J9305-75
Fig. 2 Front Brakeline Routing-YJ With ABS Brakes
REAR HOSE
PROTECTIVE
CLIP
LR.
BRAKELINE
FITTING
BOLT
AND
WASHERS
R.F.
BRAKELINE
(FROM
PROP
VALVE)
LF.
BRAKE
HOSE
J9005-2
Fig. 3 Brakeline Routing-YJ With Standard Brakes

5 - 22 BRAKELINES AND VALVES J
BRAKE REAR VENT
LEFT BRAKELINE RIGHT

REAR RETAINING REAR
BRAKELINE CLIP (TYPICAL) BRAKELINE J91G&40
Fig. 4 Rear Brakeline Routing—XJ With Standard Brakes
J9305-82
Fig. 5 Rear Brakeline Routing—XJ With ABS Brakes

BRAKELINES AND VALVES 5 - 23
J
Fig. 6 Rear Brakeline Routing—YJ With ABS Brakes

5 - 24 DISC BRAKES
J
DISC BRAKES
INDEX
page page
Caliper Assembly—2-Wheel Drive Models 32 Disc Brake Rotor Runout 34
Caliper Assembly—4-Wheel Drive Models . . . . . . 28 Disc Brake Rotor Thickness . . . . . . . . . . . . . . . . 34
Caliper Cleaning and Inspection—2-Wheel Drive Disc Brake Rotor Thickness Variation . . . . . . . . . 34
Models 32 Disc Brakeshoe Installation—2-Wheel Drive
Caliper Cleaning and Inspection—4-Wheel Drive Models 30
Models 27 Disc Brakeshoe Installation—4-Wheel Drive
Caliper Disassembly—2-Wheel Drive Models . . . . 31 Models 25
Caliper Disassembly—4-Wheel Drive Models . . . . 26 Disc Brakeshoe Removal—2-Wheel Drive Models . 29
Caliper Installation—2-Wheel Drive Models . . . . . 33 Disc Brakeshoe Removal—4-Wheel Drive Models . 24
Caliper Installation—4-Wheel Drive Models . . . . . 28 Rotor and Hub Installation-2-Wheel Drive XJ . . . 34
Caliper Removal—2-Wheel Drive Models . . . . . . . 31 Rotor and Hub Removal-2-Wheel Drive XJ . . . . 33
Caliper Removal—4-Wheel Drive Models . . . . . . . 26 Rotor Installation-4-Wheel Drive XJ/YJ . . . . . . . 34
Disc Brake Rotor Refinishing 35 Rotor Removal—4-Wheel Drive XJ/YJ 34
DISC BRAKESHOE REMOVAL—4-WHEEL DRIVE

MODELS
(1) Raise vehicle and remove front wheels.
(2) Drain small amount of fluid from master cylin
der front brake reservoir with suction gun.
(3) Bottom caliper piston in bore with C-clamp. Po
sition clamp screw on outboard brakeshoe and clamp
frame on rear of caliper. Typical C-clamp attachment
is shown in Figure 1. Do not allow clamp screw to
bear directly on outboard shoe retainer spring.
Use wood or metal spacer between shoe and
clamp screw if necessary.
Fig. 2 Removing/Installing Caliper Mounting Bolts
Fig. 1 Bottoming Caliper Piston With C-Clamp

(4) Remove caliper mounting bolts (Fig. 2).
(5) Tilt top of caliper outward. Use pry tool if nec
essary (Fig. 3).
(6) Lift caliper off steering knuckle (Fig. 4). Fig. 3 Tilting Caliper Outward
(7) If original brakeshoes will be used, keep ward until retainer spring clears caliper. Press oppo
them in sets left and right as they are not inter site end of shoe inward to disengage shoe lug and
changeable. rotate shoe up and out of caliper (Fig. 5).
(8) Remove outboard shoe. Press one end of shoe (9) Remove inboard shoe. Grasp ends of shoe and
inward to disengage shoe lug. Then rotate shoe up- tilt shoe outward to release springs from caliper pis-
(11) Wipe caliper off with shop rags or towels. Do
not use compressed air. Compressed air can un
INBOARD seat dust boot and force dirt into piston bore.
SHOE
(12) Inspect condition of caliper piston dust boot
(Fig. 7). Overhaul caliper if there is evidence of leak
age past piston and dust boot. Then inspect caliper
bushings and boots (Fig. 7). Replace boots if torn or
cut. If bushings or boots are damaged, replace them.
J9005-31 PISTON
* ^DUST
Fig. 4 Caliper Removal BOOT
SHOE LOCATING
SPRING LUG
OUTBOARD
BRAKESHOE
J9105-30
Fig. 7 Inspect Caliper Dust Boots And Bushings

DISC BRAKESHOE INSTALLATION—4-WHEEL
DRIVE MODELS
(1) Clean brakeshoe mounting ledge slide surfaces
LOCATING
of steering knuckle with wire brush. Then apply
LUG light coat of Mopar multi mileage grease to slide sur
faces (Fig. 8).
Fig. 5 Removing Outboard Brakeshoe (2) Lubricate caliper pins and bushings (Fig. 7)
with GE 661 or Dow 111 silicone grease.
INBOARD
BRAKESHOE
J9005-82
J9105-29
Fig. 6 Removing Inboard Brakeshoe
ton (Fig. 6). Then remove shoe from caliper. Fig. 8 Caliper Lubrication Points
(10) Support caliper on box, mechanics stool, or (3) Keep new or original brakeshoes in sets, D o
similar device. Do not allow brake hose to sup not interchange them.
port caliper weight.
5 - 26 DISC BRAKES
(4) Install inboard shoe in caliper (Fig. 9). Be sure

J
TOP
shoe retaining springs are fully seated in caliper piston. LEDGE
(5) Install outboard shoe in caliper (Fig. 10). Start
one end of shoe in caliper. Rotate shoe downward and
into place until shoe locating lugs and shoe spring
are seated.
BOTTOM
LEDGE
J9005-35
Fig. 11 Caliper Installation
(10) Pump brake pedal until caliper pistons and
brakeshoes are seated.
(11) Top off brake fluid level if necessary. Use Mo
par brake fluid or equivalent meeting SAE J1703
and DOT 3 standards only.
CALIPER REMOVAL—4-WHEEL DRIVE MODELS

(2) Remove caliper mounting bolts (Fig. 2).
(3) Rotate caliper rearward by hand or with pry
tool (Fig. 3). Then rotate caliper and brakeshoes off
mounting ledges.
(4) Remove caliper hose fitting bolt and disconnect
front brake hose at caliper. Discard fitting bolt wash
LOCATING
L U G
ers. They are not reusable and should be replaced.
J9005-83
(5) Remove caliper from vehicle.
Fig. 10 installing Outboard Brakeshoe CALIPER DISASSEMBLY—4-WHEEL DRIVE
(6) Verify that locating lugs on outboard shoe are MODELS
seated in caliper (Fig. 4). (1) Remove brakeshoes from caliper.
(7) Install caliper. Position notches at lower end of (2) Pad interior of caliper with minimum, 2.54 cm
brakeshoes on bottom mounting ledge (Fig. 11). Then (1 in.) thickness of shop towels or rags (Fig. 12). Tow
install caliper over rotor and seat upper ends of els are needed to protect caliper piston during re
brakeshoes on top mounting ledge (Fig. 9). moval.
(3) Remove caliper piston with short bursts of low
CAUTION: Before securing the caliper, be sure the
pressure compressed air. Direct air through fluid in
caliper brake hose i s not twisted, kinked or touch
let port and ease piston out of bore (Fig. 13).
ing any chassis components. Also be sure the hose
is clear of all suspension and steering components. CAUTION: Do not blow the piston out of the bore
Loosen and reposition the hose if necessary. with sustained air pressure. T h i s could result in a
cracked piston. U s e only enough air pressure to
(8) Install and tighten caliper mounting bolts to
ease the piston out. In addition, N E V E R attempt to
10-20 N*m (7-15 ft. lbs.) torque.
catch the piston as it leaves the bore. T h i s will re
(9) Install wheels. Tighten lug nuts to 102 N*m (75
ft. lbs.) torque. sult in personal injury.
DISC BRAKES 5 - 27
Fig. 14 Removing Caliper Piston Dust Boot
Fig. 15 Removing Caliper Piston Seal
Fig. 13 Removing Caliper Piston

(4) Remove caliper piston dust boot (Fig, 14). Col
lapse boot with suitable tool and remove and discard
boot.
(5) Remove and discard caliper piston seal with Fig. 16 Caliper Slide Bushing And Boot
wood or plastic tool (Fig. 15). Do not use metal tools
Wipe the caliper and piston dry with lint free tow
as they will scratch piston bore.
els or use low pressure compressed air.
(6) Remove caliper slide bushings and boots (Fig.
Inspect the piston and piston bore. Replace the cal
15).
iper if the bore is corroded, rusted, or scored. Do not
CALIPER CLEANING AND INSPECTION—4-WHEEL hone the caliper piston bore. Replace the caliper if
DRIVE MODELS the bore is damaged.
Clean the caliper and piston with clean brake fluid Inspect the caliper piston. The piston is made from
or Mopar brake cleaner only. Do not use gasoline, a phenolic resin (plastic material) and should be
kerosene, thinner, or similar solvents. These products smooth and clean. Replace the piston if cracked,
may leave a residue that could damage the piston chipped, or scored. Do not attempt to restore a scored
and seal.
5 - 28 DISC BRAKES J
piston surface by sanding or polishing. The piston
must be replaced if damaged.
CAUTION: Newer interchange phenolic resin and

steel caliper pistons. The seals, seal grooves, cali
per bores and piston tolerances are different for
resin and steel pistons. Do not intermix these com
ponents.
Inspect the caliper bushings and boots. Eeplace the

boots if cut or torn. Clean and lubricate the bushings
with GE 661 or Dow 111 silicone grease if necessary.
CALIPER ASSEMBLY—4-WHEEL DRIVE MODELS

(1) Coat caliper piston bore, new piston seal and
piston with clean, fresh brake fluid.
(2) Lubricate caliper slide bushings and interior of Fig. 18 Installing Piston Seal
bushing boots with GE 661 or Dow 111 silicone PISTON
grease.
(3) Install bushing boots in caliper first. Then in
sert bushing into boot and push bushing into place
(Fig. 17).
BOOT
Fig. 17 installing Slide Bushings And Boots

(4) Install new piston seal in caliper bore. Press
seal into seal groove with finger (Fig. 18).
(5) Install dust boot on caliper piston (Fig. 19).
Slide boot over piston and seat boot in piston groove.
(6) Start caliper piston in bore by hand (Fig. 20).
Use a turn and push motion to work piston into seal.
Fig. 20 Installing Caliper Piston
Once piston is started in seal, press piston only part
way into bore. CALIPER INSTALLATION-4-WHEEL DRIVE
(7) Apply light coat of GE 661 or Dow 111 silicone MODELS
grease to indicated areas (circumference) of piston (1) Install brakeshoes in caliper (Figs. 9, 10).
and caliper boot groove (Fig. 21). Grease serves as (2) Connect brake hose fitting to caliper but do not
corrosion protection for these areas. tighten fitting bolt completely at this time. Be sure
(8) Press caliper piston to bottom of bore. to use new washers on fitting bolt to avoid leaks
(9) Seat dust boot in caliper with Installer Tool (Fig. 23).
C-4842 and Tool Handle C-4171 (Fig. 22). (3) Install caliper. Position mounting notches at
(10) Install caliper bleed screw if removed. lower end of brakeshoes on bottom mounting ledge
DISC IRA1ES 5 - 29
J
FRONT
BRAKE
HOSE FITTING
•WASHERS
APPLY LIGHT COAT OF

SILICONE GREASE TO THESE
AREAS BEFORE INSTALLING
DUST BOOT
PISTON -
SEAL J9005-24 J9Q05-36
Fig. 21 Typical Caliper/Piston Areas To Be Lightly Fig. 23 Front Brake Hose And Fitting Components
Coated With Silicone Grease
(6) Install wheels. Tighten lug nuts to 102 N*m (75
ft. lbs.) torque.
HANDLE
C-4171 (7) Bleed brake system. Refer to procedures in Ser
vice And Adjustments section.
DISC BRAKESHOE REMOVAL—2-WHEEL DRIVE

MODELS
(1) Partially drain master cylinder reservoirs with
suction gun. Do not drain reservoirs completely.
(2) Loosen wheel lug nuts and raise vehicle front
INSTALLER
end.
C-4842 (3) Press caliper piston to bottom of piston bore
with C-clamp (Fig. 1).
CALIPER B O S S
J9005-77
Fig. 22 Seating Dust Boot In Caliper

OUTBOARD
(Fig. 11). Then rotate caliper over rotor and seat BRAKESHOE
notches at upper end of shoes on mounting ledge
(Fig. 11).
(4) Coat caliper slide pins with GE 661 or Dow 111
silicone grease. Then install and tighten pins to
10-20 N-m (7-15 ft. lbs.) torque. Fig. 1 Bottoming Caliper Piston With C-Clamp
(5) Position front brake hose clear of all chassis (4) Remove caliper slide pins (Fig. 2).
components and tighten caliper fitting bolt to 31 N*m (5) Remove caliper from support bracket (Fig. 3).
(23 ft. lbs.) torque. (6) Support caliper on box or suspend caliper from
body or suspension component with wire. Do not al
CAUTION: Be sure the brake hose is not twisted or low brake hose to support caliper weight.
kinked at any point. Also be sure the hose is clear
(7) Hold lower anti-rattle clip against support
of all steering and suspension components. Loosen bracket and remove outboard brake shoe (Fig. 4).
and reposition the hose if necessary. (8) Remove inboard brakeshoe and both anti-rattle
clips (Fig. 5).
5 - 30 DISC BRAKES
Fig. 2 Removing Caliper Slide Pins
Fig. 4 Removing Outboard Brakeshoe
INBOARD
SHOE
J8905-42
Fig. 3 Removing Caliper From Support Bracket

(9) Wipe caliper off with shop towel only. Do not
use compressed air to remove dirt from caliper
exterior. This could unseat caliper dust boot and ANTI-
force grit into piston bore. RATTLE
CLIP
(10) Inspect the caliper. If leakage is evident, re
move and overhaul caliper.
DISC BRAKESHOE INSTALLATION—2-WHEEL Fig. 5 Removing Inboard Brakeshoe

DRIVE MODELS (4) Install inboard brakeshoe (Fig. 5). Be sure shoe
(1) Clean slide surfaces of caliper and support is engaged in anti-rattle clip and support bracket.
bracket with wire brush and emery cloth (Fig. 6). (5) Install outboard brakeshoe (Fig. 4). Be sure
(2) Lubricate caliper and bracket slide surfaces shoe is engaged in clip and support bracket.
with Mopar multi mileage grease (Fig. 6). (6) Install remaining anti-rattle clip.
(3) Install anti-rattle clip on trailing end of sup (7) Install caliper in support bracket.
port bracket. Split end of clip faces away from rotor
(Fig. 5).
DISC BRAKES 5 - 31
J
CALIPER SUPPORT
SLIDE BRACKET
SURFACES SLIDE
SURFACES
CALIPER
B R A K E LINE
BOLT
CALIPER
SLIDE
SURFACES
J8905-45
WASHERS J8905-46
Fig. 6 Slide Surface Lubrication Points
Fig. 7 Caliper Brakeline Connection
C A U T I O N ; B e f o r e s e c u r i n g the caliper, b e s u r e t h e
caliper brake h o s e is not t w i s t e d , kinked or t o u c h e a s e the piston out. In addition, N E V E R attempt t o
ing any c h a s s i s c o m p o n e n t s . L o o s e n and r e p o s i c a t c h the piston a s it l e a v e s t h e b o r e . T h i s will re
tion the h o s e if n e c e s s a r y . sult in p e r s o n a l injury.
#
(8) Install and tighten caliper slide pins to 41 N m
(9) Install wheels and lower vehicle.
(10) Pump brake pedal until caliper pistons and
brakeshoes are seated.
(11) Top off master cylinder fluid level if neces
sary.
CALIPER REMOVAL—2-WHEEL DRIVE MODELS

(2) Remove caliper slide pins (Fig. 2).
(3) Remove caliper from support bracket.
(4) Remove front brake hose fitting bolt and re
move hose (Fig. 7). Retain fitting bolt but discard
washers which should not be reused.
CALIPER D I S A S S E M B L Y — 2 - W H E E L DRIVE
MODELS
(1) Pad interior of caliper with shop towels to pro SHOP TOWELS
J8905-47
tect piston during removal (Fig. 8).
(2) Remove caliper piston with short bursts of low Fig. 8 Removing Caliper Piston
pressure compressed air (Fig. 8). Use only enough air
(3) Remove and discard piston seal and dust boot
pressure to ease piston out of bore.
(Fig. 9).
C A U T I O N : D o not b l o w t h e piston out o f t h e b o r e (4) Remove caliper inner and outer bushings (Fig.
with sustained air p r e s s u r e . T h i s c o u l d result in a 9).
c r a c k e d piston. U s e o n l y e n o u g h air p r e s s u r e t o (5) Replace mounting pins and bushings (Fig. 9) if
corroded or damaged.
(6) Remove caliper bleed screw and cap (Fig. 9). CALIPER A S S E M B L Y — 2 - W H E E L DRIVE MODELS
(1) Coat caliper piston bore, piston and new piston
y ^ C - ^ S L I D E P I N
seal with brake fluid.
(2) Install new seal in piston bore groove by hand.
CALIPER Do not use any tools to install seal.
INNER AND
OUTER BUSHINGS (3) Apply light coat of GE 661 or Dow 111 silicone
grease to indicated areas (circumference) of piston
and caliper boot groove (Fig. 10). Grease acts as cor
rosion protection for coated areas.
ANCHOR
PISTON
PLATE SEAL
DUST
INBOARD B O O T
SHOE
APPLY LIGHT COAT OF

ANTI-RATTLE SILICONE GREASE TO THESE
CLIPS AREAS BEFORE INSTALLING
DUST BOOT
OUTBOARD
SHOE J9105-33
Fig. 9 Caliper Components—2-Wheel Drive PISTON

SEAL J9005-24
C A L I P E R CLEANING A N D INSPECTION—2-WHEEL
D R I V E MODELS Fig. 10 Typical Caliper/Piston Areas To Be Coated
Clean the caliper and piston with Mopar brake With Silicone Grease
cleaning solvent or clean brake fluid only. Do not use (4) Slide metal retainer part of new dust boot over
gasoline, kerosene, thinner, or similar solvents for open end of piston (Fig. 11).
cleaning purposes. These products will leave a resi (5) Pull retainer rearward until boot lip seats in
due that could eventually damage the piston and groove at open end of piston (Fig. 11).
seal.
Wipe the caliper and piston dry with lint free tow
els or use low pressure compressed air.
Inspect the caliper piston. The piston is made from
a phenolic resin (plastic material) and should be
smooth and clean.
Replace the piston if cracked, chipped, or scored.
Do not attempt to restore a scored piston surface by
sanding or polishing. The piston must be replaced if
damaged.
CAUTION: Never interchange phenolic resin and

steel caliper pistons. T h e seals, seal grooves, cali
per bores and piston tolerances are different f o r
resin and steel pistons. Do not intermix these com
ponents.
Replace the caliper if the piston bore is damaged or CALIPER

BOOT LIP
PISTON
corroded. Do not attempt to restore a damaged piston IN PISTON
GROOVE
bore by honing. If the bore is corroded or scored, re
J8905-49
place the caliper.
Inspect the caliper bushings and boots. Replace the Fig. 11 Installing Dust Boot On Piston
boots if cut or torn. Clean and lubricate the bushings
(6) Push metal retainer part of boot forward until
with GE 661 or Dow 111 silicone grease if necessary.
flush with rim at open end of piston. Then snap boot
folds in place (Fig. 12).
DISC BRAKES 5 - 33
J
DUST CALIPER INSTALLATION-2-WHEEL DRIVE
MODELS
(1) Lubricate slide surfaces of caliper with Mopar
multi mileage grease (Fig. 6).
(2) Clean support plate slide surfaces with wire
brush and coat with Mopar multi mileage grease.
(3) Install caliper.
(4) Install and tighten caliper slide pins to 41 N»m
(30 ft-lbs) torque.
(5) Connect brakeline to caliper (Fig.7). To avoid
leaks, use new washers to secure line fitting.
(6) Tighten brakeline fitting bolt to 31 N*m (23 ft.
lbs.) torque.
CAUTION: Be sure to position the front brake hose
away from all suspension components before tight
ening the fitting bolt (Fig. 14). Also be sure the
hose i s not twisted or kinked at any point. Loosen
and reposition the hose if necessary.
POSITION BRAKELINE
Fig. 12 Snapping Dust Boot Folds In Place
(7) Install piston in caliper bore with a twisting
motion. Do not push piston straight in as seal
may become unseated.
(8) Work piston to bottom of caliper bore.
(9) Seat metal retainer part of dust boot in caliper
(Fig. 13).
Fig. 14 Caliper Brakeline Position

(7) Install wheel and lower vehicle.
(8) Apply brakes several times to seat caliper pis
tons.
(9) Top off master cylinder fluid level with Mopar
brake fluid.
ROTOR AND HUB REMOVAL—2-WHEEL DRIVE XJ

(1) Raise vehicle and remove wheels.
Fig. 13 Seating Piston Dust Boot (2) Remove caliper. ,
(3) Remove grease cap (Fig. 1).
(10) Install bleeder screw and cap. (4) Remove cotter pin and nut retainer (Fig. 1).
(11) Install new inner and outer bushings in cali (5) Remove nut lock, bearing nut and front bearing
per (Fig. 9). (Fig. 1).
5 - 34 DISC BRAKES J
(6) Remove rotor from spindle (Fig. 1).

(7) Remove grease seal and rear bearing (Fig. 1).
(8) Remove rotor shield if necessary.
PIN
Fig. 2 Rotor And Hub-4-Wheel Drive XJ/YJ
J9005-51 DISC BRAKE ROTOR THICKNESS

Measure rotor thickness at the center of the brake-
Fig. 1 Rotor And Bearings—2-Wheel Drive XJ shoe contact surface. Replace the rotor if worn below
ROTOR AND HUB INSTALLATION—2-WHEEL minimum thickness. Also replace the rotor if refin-
ishing would reduce thickness below the allowable
DRIWE XJ
minimum.
(1) Clean and repack bearings with Mopar or
Rotor minimum thickness for YJ and 4-wheel drive
equivalent wheel bearing grease. Then coat spindle,
XJ models is 22.7 mm (0.89 in.). Minimum rotor
bearing races and rotor hub cavity with bearing
thickness for 2-wheel drive XJ/MJ models is 22 mm
grease.
(0.866 in.).
(2) Install rear bearing and new grease seal in ro
tor. DISC BRAKE ROTOR RUNOUT
(3) Install rotor on spindle. Check rotor lateral runout with a dial indicator
(4) Install front bearing, washer and bearing nut. (Fig. 3 ) . Excessive lateral runout will cause brake
(5) Install wheel. pedal pulsation and rapid, uneven wear of the brake-
(6) Tighten wheel bearing nut to 23-24 N-m (17-25 shoes.
ft. lbs.) torque while rotating wheel. Then loosen Maximum allowable rotor runout for all models is
#
bearing nut 1/2 turn and retighten to 2 N m (19 in. 0.12 mm (0.005 in.).
lbs.) torque.
(7) Install nut lock and new cotter pin.
(8) Coat interior of grease cap with bearing grease
and install it in rotor hub.
(9) Remove wheel.
(10) Install caliper and reinstall wheel.
(11) Lower vehicle.
ROTOR R E M O V A L — 4 - W H E E L DRIVE XJ/YJ

(1) Raise vehicle and remove wheel.
(2) Remove caliper.
( 3 ) Remove retainers securing rotor to hub studs
(Fig. 2).
(4) Remove rotor from hub (Fig. 2).
(5) If rotor shield requires service, remove front
hub and bearing assembly.
INDICATOR ^0
J8905-68
I O f t r t c
ROTOR I N S T A L L A T I O N - 4 - W H E E L DRIVE XJ/YJ

(1) Install rotor on hub. Fig. 3 Checking Rotor Lateral Runout
(2) Install caliper.
(3) Install new spring nuts on wheel studs.
DISC BRAKE ROTOR THICKNESS VARIATION
(4) Install wheel and lower vehicle. Variations in rotor thickness will cause pedal pul
sation, noise and shudder.
J DISC BRAKES 5 - 35
Measure rotor thickness at four to six points

around the rotor face. Position the micrometer ap
proximately 2 cm (3/4 in.) from the rotor outer cir
cumference for each measurement (Fig. 4).
Thickness should not vary by more than 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
Fig. 4 Measuring Rotor Taper And Thickness

Variation
DISC BRAKE ROTOR REFINISHING
Rotor brake surfaces can be refinished by sanding
and/or machining in a disc brake lathe. The lathe
must be capable of machining both rotor surfaces si
multaneously with dual cutter heads (Fig. 5). Equip
ment capable of machining only one side at a
time will produce a tapered rotor. The lathe
should also be equipped with a grinder attachment,
or dual sanding discs for final cleanup or light refin-
ishing (Fig. 5). J8905-70
If the rotor surfaces only need minor cleanup of
Fig. 5 Rotor Refinishing Equipment
rust, scale, or minor scoring, use abrasive discs to
clean up the rotor surfaces. However, when a rotor is
scored or worn, machining with cutting tools will be
required.
CAUTION: Do not refinish a rotor if machining

would cause the rotor to fall below minimum allow
able thickness.
5 - 36 DISC BRAKES
Fig. 6 Correct Final Surface Finish

DRUM BRAKES 5 - 37
DRUM BRAKES
INDEX
page page
Brake Drum Refinishing 39 Wheel Cylinder Installation 39
Drum Brakeshoe Installation . 37 Wheel Cylinder Overhaul (Figs. 1 , 2, 3) 39
Drum Brakeshoe Removal (Figs. 1 and 2) . . . . . . 37 Wheel Cylinder Removal . . . . . . . . . . . . . . . . . . . 39
DRUM BRAKESHOE REMOVAL (Figs. 1 and 2) DRUM BRAKESHOE INSTALLATION

(1) Raise vehicle and remove rear wheels. (1) Clean and lubricate anchor pin with Mopar
(2) Remove and discard spring nuts securing multi mileage grease.
drums to wheel studs. (2) Clean support plate shoe contact surfaces. Then
(3) Remove brake drums. If drums prove difficult apply Mopar multi mileage grease to contact surfaces
to remove, retract brakeshoes. Remove access plug at (Figs. 3 and 4).
the rear of backing plate and back off adjuster screw (3) Lubricate adjuster cable guides, adjuster screw
with brake tool and screwdriver. and pivot, parking brake lever and lever pivot pin
(4) Remove U-clip and washer securing adjuster with Mopar multi mileage grease.
cable to parking brake lever. (4) Attach parking brake lever to secondary brake-
(5) Remove primary and secondary return springs shoe with washer and new U-clip.
from anchor pin with Brake Spring Plier Tool 8078. (5) Remove wheel cylinder clamps.
(6) Remove holddown springs, retainers and pins (6) Attach parking brake cable to lever.
with Retaining Spring Tool C-4070. (7) Install brakeshoes on support plate. Secure
(7) Install Spring Clamps C-416 on wheel cylinders shoes with new holddown springs, pins and retainers.
to hold pistons in place. (8) Install parking brake strut and spring.
(8) Remove adjuster lever, adjuster screw and (9) Install guide plate and adjuster cable on anchor
spring. pin.
(9) Remove adjuster cable and cable guide. (10) Install primary and secondary return springs.
(10) Remove brakeshoes and parking brake strut. (11) Install adjuster cable guide on secondary shoe.
(11) Disconnect cable from parking brake lever (12) Lubricate and assemble adjuster screw (Fig.
and remove lever. 5).
(13) Install adjuster screw, spring and lever and
connect to adjuster cable.
CYLINDER-
RIGHT REAR TRAILING TO-SUPPORT SEAL
BRAKE ASSEMBLY ADJUSTER SHOE
LEVER
HOLDDOWN SPRING
SPRING AND HOLDDOWN PINS
RETAINERS
ADJUSTER ACCESS
CABLE PLUGS
ADJUSTER
LEVER
SUPPORT PLATE
CABLE
GUIDE PARK
BRAKE
SHOE 'STRUT
RETURN ADJUSTER AND
SPRINGS SCREW SPRING
ASSEMBLY
HOLDDOWN
SPRING AND
RETAINERS J9005-13
Fig. 1 Nine Inch Drum Brake Components

e - 38 DRUM BRAKES J
A D J U S T E R CABLE
ANCHOR
PIN
HOLDDOWN PIN
ADJUSTER
LEVER
SHOE
SPRING
LEFT REAR
BRAKE ASSEMBLY SPRING
RETAINERS
19005-53
Fig. 2 Ten Inch Drum Brake Components

SUPPORT
ANCHOR PLATE SHOE
PIN ANCHOR CONTACT
PIN SURFACE
SHOE CONTACT
SURFACES J9005-14
Fig. 3 Shoe Contact Surfaces—9-Inch Brake

Support Plate
SHOE
(14) Adjust shoes to drum with brake gauge and CONTACT
SURFACE
install brake drum.
J8905-73
Fig. 4 Shoe Contact Surfaces-10-Inch Brake Support Plate
WASHER SOCKET S T A M P E D I.D. L E T T E R :
L - L E F T BRAKE
R—RIGHT BRAKE
ADJUSTER
SCREW
STAR
BUTTON WHEEL
J9005-16
Fig. 5 Adjuster Screw Components—9-Inch Brake
J DRUM BRAKES 5 - 39
WHEEL CYLINDER REMOVAL PUSH RODS

(1) Raise vehicle and remove wheel.
(2) Disconnect brakeline at wheel cylinder.
(3) Remove brakeshoes.
(4) Remove bolts attaching wheel cylinder to sup
port plate and remove cylinder.
WHEEL CYLINDER OVERHAUL (Figs. 1 , 2, 3)

(1) Remove links.
(2) Remove dust boots.
SUPPORT
(3) Remove cups and pistons. Discard cups. PLATE
(4) Remove and discard spring and expander. WHEEL CYLINDER J9005-11
(5) Remove bleed screw.
Fig. 3 Wheel Cylinder Mounting
BLEED PISTON
SCREW- CYLINDER CUP PISTON (5) Install brakeshoes. Adjust shoes to drum with
LINK
brake gauge.
farm (6) Install brake drums and lower vehicle.
COMPRESSION BOOT (7) Fill master cylinder and bleed brakes.
SPRING A N D
EXPANDERS
BRAKE DRUM REFINISHING
Brake drums can be machined to restore the brak
J9005-54 ing surface. Use a brake lathe to clean up light scor
Fig. 1 Wheel Cylinder-With 9-Inch Brake ing and wear.
CUP E X P A N D E R S CAUTION: Never refinish a brake drum if machining

AND SPRING
will cause the drum to exceed maximum allowable
brake surface diameter.
Brake drums that are warped, distorted, or se

verely tapered should be replaced. Do not refinish
WHEEL drums exhibiting these conditions. Brake drums that
CYLINDER-
are heat checked or have hard spots should also be
replaced.
BLEEDER S C R E W — * j
J9005-15 The maximum allowable diameter for the drum
Fig. 2 Wheel Cylinder—With 10-Inch Brake braking surface is usually indicated on the drum
outer face (Fig. 4).
(6) Clean cylinder, pistons and links with Mopar
brake cleaner. DRUM REFINISH LIMIT
(IN INCHES OR
(7) Inspect cylinder bore and pistons. Light discolora ^MILLIMETERS)
tion of bore is acceptable. However, replace cylinder if
bore and pistons are scored, pitted, or corroded. Do not
hone cylinder bores or polish pistons. Replace cyl
inder as an assembly if bore is damaged.
(8) Install bleed screw.
(9) Coat cylinder bore, pistons, cups and expander
with brake fluid and reassemble cylinder compo
nents. Be sure piston cup lips face expander.
WHEEL CYLINDER INSTALLATION

(1) Position wheel cylinder on support plate (Fig.
3).
J9005-55
(2) Start brakeline in wheel cylinder fitting.
(3) Install cylinder mounting bolts (Fig. 3). Fig. 4 Brake Drum Refinish Limit
Tighten bolts to 10 Nnn (90 in. lbs.) torque.
(4) Tighten brakeline fitting to 15 N*m (132 in.
lbs.) torque.
i - 40 PARKING BRAKES J
PARKING BRAKES
INDEX
page page
Parking Brake Cables—XJ . . . . . . . . . . . . . . . . . . 42 Parking B r a k e Lever—XJ .................. 40
Parking Brake Cables—YJ 43 Parking Brake Pedal—YJ .. ............ 41
PARKING BRAKE L E ¥ E R - X J (7) Remove console cover screws (Fig. 3).

(8) On models with power mirror switch, pry
LEVER REMOVAL—WITH CONSOLE switch out of console cover and disconnect switch
(1) Release parking brakes. connector (Fig. 3).
(2) Raise vehicle and remove equalizer nut and
washer from lever operating rod (Fig. 1).
Fig. 1 Lever Operating Rod

(3) Lower vehicle.
(4) On models with manual transmission, remove
shift knob, boot and bezel.
(5) On models with automatic transmission, re
move shift handle cap and remove plunger, spring Fig. 3 Console Cover Screws And Power Mirror
and T-lock (Fig. 2). Switch Connector
(6) Remove shift handle and shift bezel (Fig. 2).
(9) Remove console cover from base (Fig. 4).
(10) Remove console base.
(11) Disconnect brake warning light wire connec
tor at lever (Fig. 5).
(12) Remove lever attaching bolts and remove le
ver (Fig. 6).
LEVER INSTALLA TION- WITH CONSOLE

(1) Position lever on floorpan and install lever at
taching bolts (Fig. 6).
(2) Connect brake warning light wire connector
(Fig. 5).
(3) Install console base and cover (Fig. 4).
(4) Connect power mirror switch wire to switch
and install switch in console cover.
(5) On automatic transmission models, install shift
Fig. 2 Automatic Transmission Shift Handle bezel and shift handle (Fig. 2).
PARKING BRAKES 5 - 41
Fig. 6 Removing Parking Brake Lever

(7) Raise vehicle and connect equalizer to lever op
erating rod.
(8) Adjust parking brakes as described in Service
Adjustments section.
LEVER REMOVAL—WITHOUT CONSOLE

(1) Raise vehicle and disconnect equalizer from le
ver operating rod (Fig. 1).
(2) Lower vehicle.
(3) Raise lever cover at rear and tilt it forward
(Fig. 7).
(4) Drill out cover retaining rivets and remove
cover (Fig. 7).
(5) Disconnect brake warning light wire at lever
(Fig. 5).
(6) Remove lever retaining bolts (Fig. 6) and re
move lever.
LEVER INSTALLATION- WITHOUT CONSOLE

(1) Position lever on floorpan and install mounting
bolts.
(2) Connect brake warning light wire to lever.
(3) Install lever cover. Secure cover with new riv
ets.
(4) Raise vehicle.
(5) Connect lever operating rod to equalizer.
J9205-33 Adjustment section.
Fig. 5 Brake Warning Light Wire Connector PARKING BRAKE P E D A L — Y J
Location
(6) On manual transmission models, install boot, PEDAL REMOVAL
bezel and shift knob. (1) Raise vehicle.
(2) Loosen equalizer nuts until front cable is slack
(Fig. 8).
5 - 42 PARKING BRAKES
J
(7) Remove bolt securing pedal assembly to instru
ment panel (Fig. 9).
(8) In engine compartment, remove pedal mount
ing stud nuts.
(9) Remove pedal assembly from panel.
(10) Disengage front cable from retainer (Fig. 9).
(11) Squeeze cable clip (Fig. 9) and pull cable out
of pedal frame.
(12) Remove pedal assembly.
PARKING MOUNTING
Fig. 9 Parking Brake Pedal Assembly— YJ

PEDAL INSTALLATION-YJ
(1) Connect front cable to pedal retainer.
(2) Position pedal assembly on panel and install
mounting stud nuts and pedal-to-dash bolt.
(3) Install ground wire on upper end of pedal-to-
dash bolt and secure wire with attaching nut.
(4) Connect warning light switch wire to pedal
connector.
(5) Install dash-to-instrument panel brace rod, if
equipped.
J91G5-22 (6) Raise vehicle and adjust brake cables. Refer to
procedure in Service Adjustment section.
Fig. 8 Front Cable And Equalizer—YJ
PARKING BRAKE CABLES-XJ
(3) Lower vehicle.
(4) Remove dash-to-instrument panel brace rod, if REAR CABLE REPLACEMENT
equipped. (1) Raise vehicle and loosen equalizer nuts until
(5) Disconnect warning light switch wire from rear cables are slack.
pedal assembly. (2) Disengage cable from equalizer and remove ca
(6) On some YJ models, a ground wire may be at ble clip and spring (Fig. 10).
tached to upper end of bolt that secures parking (3) Remove rear wheel and brake drum.
brake pedal to instrument panel. Wire is secured (4) Remove secondary brakeshoe and disconnect
with a nut. Be sure to remove nut and detach ground cable from lever on brakeshoe.
wire before proceeding. If this wire is not removed (5) Compress cable retainer with worm drive hose
beforehand, wire and harness could be damaged clamp (Fig. 11) and remove cable from backing plate.
when pedal assembly bolt is removed. Ground wire (6) Install new cable in backing plate. Be sure ca
and attaching nut are accessible from under instru ble retainer is seated.
(7) Attach cable to lever on brakeshoe and install
ment panel.
brakeshoe on backing plate.
PARKING BRAKES 5 - 43
J (8) Adjust brakeshoes to drum with brake gauge. PARKING BRAKE CABLES-YJ
(9) Install brake drum and wheel.
(10) Engage cable in equalizer and install equal FRONT CABLE REPLACEMENT
izer nuts (Fig. 10). (1) Raise vehicle.
(11) Adjust parking brakes as described in Service (2) Remove equalizer nuts (Fig. 12).
Adjustment section. (3) Remove front cable from equalizer (Fig. 12).
(4) Remove cable-to-frame bracket clip.
(5) Lower vehicle.
(6) Move front carpeting away from pedal.
(7) Compress clip securing cable to pedal frame
(Fig. 11). Use hose clamp to compress clip.
(8) Disconnect cable from pedal retainer and re
move cable.
(9) Remove grommet (Fig. 12) from old cable and
transfer it to new cable.
(10) Install new cable in floorpan and connect it to
pedal assembly.
(11) Seat cable grommet in floorpan.
(13) Install cable-to-frame retaining clip.
(14) Insert cable in equalizer and install equalizer
washer and nuts.
Adjustment section.
REAR CABLE REPLACEMENT-YJ

(1) Raise vehicle and loosen equalizer nuts (Fig.
12).
(2) Remove clamp and cotter pin attaching rear ca
ble to equalizer and remove cable.
(3) Remove cable clips.
(4) Remove rear wheel and brake drum.
(5) Remove secondary brakeshoe and disconnect
cable from lever on brakeshoe.
(6) Compress cable retainer with hose clamp (Fig.
11) and remove cable from backing plate.
(7) Install new cable in backing plate. Be sure ca
ble retainer lock tabs are engaged in plate.
(8) Install secondary brakeshoe.
(9) Adjust brakeshoes to brake drum and install
drum and wheel.
(10) Install cable in equalizer. Secure cable with
retainer and cotter pin.
(11) Install cable clips.
Adjustment section.
Fig. 11 Compressing Rear Cable Retainer

44 PARKING BRAKES
J
Fig. 12 Parking Brake Cables—YJ

J PARKING B R A K E S 5 - 45
BRAKE PEDAL AND SWITCH
INDEX
page page
Brake Pedal Installation 45 Brakelight Switch Installation ................ 46
Brake Pedal Removal 45 Brakelight Switch Removal 46
Brake Pedal Service 45 General Information 45
Brakelight Switch Adjustment 46
GENERAL INFORMATION DASH SUPPORT

A suspended-type brake pedal is used on all models
(Figs. 1 and 2). The pedal pivots on a pin mounted in
the pedal support bracket. The bracket is attached to
the dash and instrument panels on all models.
A plunger-type, adjustable brakelight switch is
used on all models. The switch is attached to a flange
on the pedal support bracket.
B R A K E PEDAL SERWICE
The brake pedal is a serviceable component. The
pedal, pivot pin, sleeve, pedal bushings and spacers/
washers are all replaceable parts. The pedal bracket
can also be replaced when necessary.
PEDAL PEDAL
CLIP J9105-39
Fig. 2 Brake Pedal—XJ

(5) Remove nut securing pedal shaft in support
bracket.
(6) Slide pedal shaft outward for clearance and re
move brake pedal.
(7) Remove pedal bushings if they are to be re
placed.
BRAKE PEDAL INSTALLATION

(1) Install new bushings in pedal. Lubricate bush
ings and pivot pin with Mopar multi mileage grease.
(2) Position pedal, sleeve and spacer(s) in bracket
J9105-38 and install pivot pin.
(3) Install new nut on pivot pin. Pivot pin nut is
Fig. 1 Brake Pedal—YJ specially formed and should not be reused. Be
B R A K E PEDAL REMOWAL sure to install new nut to secure pin.
(1) Remove lower trim panel and A/C duct if nec (4) ) Tighten new pivot pin nut to 27 N»m (20 ft.
essary. lbs.) on models with manual transmission. Tighten
(2) Remove steering column lower trim panel and nut to 35 N*m (26 ft. lbs.) on models with automatic
bezel. transmission.
(3) Remove necessary dash panel-to-instrument (5) Install booster push rod on pedal pin. Secure
panel brace rods. push rod with original, or new retainer clip if neces
(4) Remove retainer clip securing booster push rod sary.
to pedal. (6) Install dash brace rod, if equipped.
5 - 46 PARKING BRAKES
J
(7) Check and adjust brakelight switch if neces clearance between pedal and switch barrel is insuf
sary. Refer to procedure in this section. ficient, adjust switch position as described in step
(2).
BRAKELIGHT SWITCH REMOVAL (2) Grasp brake pedal and pull it rearward as far
The brakelight switch is mounted in the pedal sup as possible. Pedal should contact switch barrel, push
port bracket and is operated by the pedal. The switch
it rearward in retaining clip and stop at correct posi
is secured in the bracket with a retainer (Fig. 3).
tion.
(1) Remove steering column cover and lower trim
panel for switch access, if necessary. (3) Verify brakelight switch operation and proper
(2) Disconnect switch wires. clearance between switch and brake pedal.
(3) Thread switch out of retainer, or rock switch
up/down and pull it rearward out of retainer. CAUTION: Be very sure the brake pedal returns to a
(4) Inspect switch retainer. Replace retainer if fully released position after adjustment. The switch
worn, distorted, loose, or damaged. can interfere with full pedal return if too far forward.
The result will be brake drag caused by partial
BRAKELIGHT SWITCH INSTALLATION brake application.
(1) Insert replacement switch in retainer. Thread
switch into place or rock it up/down until switch PEDAL
SUPPORT BRACKET
plunger touches brake pedal.
(2) Connect switch wires.
(3) Check switch operation. Adjust switch position
if necessary. Refer to procedures in this section.
(4) Install trim panels (if removed).
BRAKELIGHT SWITCH ADJUSTMENT

(1) Check switch adjustment. Move brake pedal
forward by hand and note operation of switch
plunger. Plunger should be fully extended when
pedal free play is taken up and brake application be S W I T C H CONNECTOR
gins. Clearance of approximately 1/8 inch should ex AND HARNESS
ist between plunger and pedal at this point.

(a) If switch-to-pedal clearance is OK and brake- BRAKEUGHT SWITCH J9105-23
lights operate correctly, adjustment is not required.
(b) If switch plunger does not fully extend and Fig. 3 Brakelight Switch-XJ/YJ
J ANTILOCK BRAKE S Y S T E M (ABS) i - 47
ANTILOCK BRAKE SYSTEM (ABS)
INDEX
page page
Acceleration Switch 50 Master Cylinder 48
Combination Valve 51 Pedal Travel Sensor 48
Electronic Control Unit (ECU) 48 Power Brake Booster 48
General Information 47 System Relays 50
Hydraulic Control Unit (HCU) 47 System Warning Lights 50
Ignition Switch 50 Wheel Speed Sensors 48
GENERAL INFORMATION wheel speed sensors and axle shaft tone rings
The Jeep antilock brake system (ABS) is an elec hydraulic control unit (HCU)
tronically operated, all-wheel brake control system. tandem master cylinder with central valves
Major components include the master cylinder, vac vacuum power brake booster
uum power brake booster, ECU, hydraulic control pedal travel sensor
unit (HCU) and various control sensors (Fig. 1). The acceleration switch
ABS brake system is available on XJ and YJ models. main relay and pump motor relay
ABS warning light
FLUID POWER
RESERVOIR BRAKE pump motor sensor
COMBINATION HCU H A R N E S S
VALVE CONNECTOR J9205-2
1. HCU 8. ECU
Fig. 1 Antilock Components (XJ Shown) 2. COMBINATION VALVE 9. RIGHT REAR W H E E L
3. M A S T E R CYLINDER 10. LEFT REAR W H E E L
The antilock hydraulic system is a three channel 11. LEFT F R O N T W H E E L
4. FLUID RESERVOIR
design. The front wheel brakes are controlled indi 5. VACUUM P O W E R BOOSTER 12. RIGHT F R O N T W H E E L
vidually and the rear wheel brakes in tandem (Fig. 6. PEDAL TRAVEL S E N S O R 13. W H E E L S P E E D S E N S O R W I R E S
7. ACCELERATION S E N S O R 14. HCU H A R N E S S W I R E S
2).
The antilock system is designed to retard wheel
J9205-1
lockup during periods of high wheel slip when brak
ing. Retarding wheel lockup is accomplished by mod
Fig. 2 AntiLock System Basic Layout
ulating fluid pressure to the wheel brake units.
The ABS electronic control system is separate from H Y D R A U L I C C O N T R O L U N I T (HCU)
other electrical circuits in the vehicle. A specially The hydraulic control unit (HCU) consists of a
programmed electronic control unit (ECU) is used to valve body and pump/motor assembly (Fig. 3).
operate the system components. The valve body contains the electrically operated
System components include: solenoid valves. It is the solenoid valves that modu
• electronic control unit (ECU) late brake fluid apply pressure during antilock brak-
5 - 48 ANTILOCK B R A K E S Y S T E M (ABS)
J
ing. The valves are operated by the antilock The primary and secondary pistons each contain a
electronic control unit (ECU). central valve which is a unique feature. The valves
The HCU provides three channel pressure control are used in place of the conventional piston and seal
to the front and rear brakes. One channel controls assemblies. The valves close and open the cylinder
the rear wheel brakes in tandem. The two remaining pressure chambers during brake application and re
channels control the front wheel brakes individually. lease.
During antilock braking, the solenoid valves are The only repairable components on the ABS master
opened and closed as needed. The valves are not cylinder are the reservoir, reservoir grommets and
static. They are cycled rapidly and continuously to the connecting hoses. The cylinder itself cannot be
modulate pressure and control wheel slip and decel disassembled and is serviced only as an assembly.
eration.
The pump/motor assembly provides the extra vol POWER BRAKE BOOSTER
ume of fluid needed during antilock braking. The A dual diaphragm, vacuum operated power brake
pump is connected to the master cylinder reservoir booster is used with the ABS master cylinder (Fig.
by supply and return hoses.
4). The engine intake manifold serves as the vacuum
The pump is operated by an integral electric motor.
source for booster operation.
The DC type motor is controlled by the ECU.
The booster is mounted on the engine compartment
The pump mechanism consists of two opposing pis
tons operated by an eccentric cam. One piston sup side of the dash panel. The master cylinder is
plies the primary hydraulic circuit. The opposite mounted on attaching studs at the front of the
piston supplies the secondary hydraulic circuit. In op booster. The master cylinder central valves are di
eration, one piston draws fluid from the master cyl rectly actuated by the booster push rod.
inder reservoir. The opposing piston then pumps The pedal travel sensor is mounted in the forward
fluid to the valve body solenoids. The pump cam is face of the booster shell. The sensor plunger is actu
operated by the electric motor. ated by the booster diaphragm plate.
PUMP PEDAL TRAVEL SENSOR

AND
MOTOR
The pedal travel sensor signals brake pedal posi
tion to the antilock ECU. The sensor signal is based
on changes in electrical resistance. The resistance
changes occur in steps that are generated by changes
in brake pedal position. A resistance signal gener
ated by changing brake pedal position, will cause the
ECU to run the antilock pump when necessary.
The sensor is a plunger-type, electrical switch
VALVE
mounted in the forward housing of the power brake
BODY booster (Fig. 5). The sensor plunger is actuated by
movement of the booster diaphragm plate.
The tip on the sensor plunger is color coded. The
MOUNTING
tip must be matched to the color dot on the face of
RESERVOIR the brake booster front shell (Fig. 5).
BRACKET
PIPES
HARNESS
WHEEL SPEED SENSORS
CONNECTOR
A sensor is used at each wheel. The sensors convert
wheel speed into an electrical signal. This signal is
transmitted to the antilock electronic control unit
TOP (ECU).
VIEW A gear-type tone ring serves as the trigger mecha
1 nism for each sensor. The tone rings are mounted at
the outboard ends of the front and rear axle shafts.
Different sensors are used at the front and rear
wheels (Fig. 6). The front/rear sensors have the same
J9205-4
electrical values but are not interchangeable.
Fig. 3 AntiLock Hydraulic Control Unit (HCU)
E L E C T R O N I C C O N T R O L U N I T (ECU)
MASTER CYLINDER A separate electronic control unit (ECU) monitors,
A new style tandem master cylinder is used with operates and controls the antilock system (Fig. 7).
the ABS system (Fig. 4). It is a center feed design. The ECU contains dual microprocessors. The logic
J ANTILOCK BRAKE SYSTEM (ABS) S - 49
MASTER VACUUM
CYLINDER POWER
RESERVOIR BRAKE
BOOSTER
RESERVOIR •
HOSES
COMBINATION MASTER
VALVE CYLINDER J9205-3
Fig. 4 ABS Power Brake Booster/Master Cylinder Assembly

PLUNGER CAP
(COLOR CODED)
VACUUM
POWER
BRAKE
BOOSTER
o
FRONT
SENSOR"
11 •
PEDAL
TRAVEL
SENSOR
PICKUP
FACE J9205-6
Fig. 6 Wheel Speed Sensors

The power up voltage source for the ECU is
through the ignition switch in the On and Run posi
tions.
The antilock ECU is separate from the other vehi
cle electronic control units. It contains a self check
program that illuminates the amber warning light
when a system fault is detected. Faults are stored in
COLOR a diagnostic program memory and are accessible
DOT with the DRB II scan tool.
LOCATION
ABS faults remain in memory until cleared, or un
Fig. 5 Pedal Travel Sensor Location til after the vehicle is started approximately 50
times. Stored faults are not erased if the battery is
block in each microprocessor receives identical sensor disconnected.
signals. These signals are processed and compared si
multaneously (Fig. 8).
The ECU is located under the instrument panel. It
is located at the right side of the steering column.
5 - SO ANTILOCK BRAKE SYSTEM (ABS) J
The switch reference signal is utilized by the ECU

when all wheels are decelerating at the same speed.
Equal wheel speeds occur during braking in undiffer
entiated 4-wheel ranges.
PART
NUMBER
KEY-IN
CODE
MANUFACTURER
I.D. CODE
5 5 PIN ARROW
CONNECTOR INDICATES
FRONT OF
S E N S O R FOR
PROPER M O U N T I N G
SENSOR
PART
NUMBER J9205-9
J9205-7 Fig. 9 Acceleration Switch

Fig. 7 Anti-Lock ECU SYSTEM RELAYS
The ABS system has two relays, which are the
main and motor pump relays. The motor pump relay
is used for the motor pump only. The main relay is
•c: used for the solenoid valves and remaining system

components. The main relay is connected to the ECU
at the power control relay terminal.
MICROPROCESSOR 1
The pump motor relay starts/stops the pump motor
when signaled by the ECU. The start/stop signal to
the ECU is generated by the pedal travel sensor. Re
fer to the ABS schematic at the end of this section
for circuit details.
IGNITION SWITCH
The antilock ECU and warning light are in
standby mode with the ignition switch in Off or Ac
cessory position. No operating voltage is supplied to
the system components.
A 12 volt power feed is supplied to the ECU, re
lays, solenoid valves, and warning light when the ig
MICROPROCESSOR 2
nition switch is in the ON, Start and Run positions.
J9205-8
Refer to the ABS system schematic at the end of this
section for details.
Fig. 8 ECU Dual Microprocessor Schematic
SYSTEM WARNING LIGHTS
ACCELERATION SWITCH Two warning lights are used. The standard brake
An acceleration switch (Fig. 9), provides an addi system light is red. The antilock system light is am
tional vehicle deceleration reference during 4-wheel ber. Both lights are in the instrument cluster. The
drive operation. The switch is monitored by the anti- amber ABS light is in circuit with the ECU and op
lock ECU at all times. erates independently of the red brake light.
ANTILOCK B R A K E S Y S T E M (ABS) 5 - 51
J The amber light indicates antilock system condi COMBINATION V A L V E
tion. It is in circuit with the valve body solenoids and A combination valve is used with the ABS system
main relay. The light illuminates (flashes) at (Fig. 2). The valve contains a front/rear brake pres
start-up for the self check. The light then goes out sure switch and proportioning valve. The valve is
when the self check program determines system op connected between the master cylinder and hydraulic
eration is normal.
control unit (HCU).
If an ABS fault occurs either during the start-up
self check, or during normal operation, the amber
light remains on until the fault is corrected.
i - 52 ANTILOCK B R A K E SYSTEM OPERATION J
ANTILOCK BRAKE SYSTEM OPERATION
INDEX
page page
ABS Operation in Antilock Braking Mode 52 HCU Pump and Pedal Travel Sensor Operation . 53
ABS Operation in Normal Braking Mode 52 HCU Solenoid Valve Operation 52
Acceleration Switch Operation . . . . . . . . . . . . . . . 54 System Power-Up and Initialization . . . . . . . . . . . 52
E C U Operation 55 Wheel Speed Sensor Operation 54
SYSTEM POWER-UP AND INITIALIZATION The antilock system retards lockup during high
The antilock system is in standby mode with the slip conditions by modulating fluid apply pressure to
ignition switch in Off or Accessory position. The an the wheel brake units.
tilock electrical components are not operational. Brake fluid apply pressure is modulated according
Turning the ignition switch to On or Run position to wheel speed, degree of slip and rate of decelera
allows battery voltage to flow through the switch to tion. A sensor at each wheel converts wheel speed
the ECU ignition terminal. into electrical signals. These signals are transmitted
The ABS system is activated when battery voltage to the ECU for processing and determination of
is supplied to the ECU. The ECU performs a system wheel slip and deceleration rate.
initialization procedure at this point. Initialization The Jeep ABS system has three fluid pressure con
consists of a static and dynamic self check of system trol channels. The front brakes are controlled sepa
electrical components. rately and the rear brakes in tandem (Fig. 10). A
The static check occurs immediately after the igni speed sensor input signal indicating high slip condi
tion switch is turned to the On position. The dynamic tions activates the ECU antilock program.
check occurs when vehicle road speed reaches ap
Two solenoid valves are used in each antilock con
proximately 10 kph (6 mph). During the dynamic
trol channel (Fig. 11). The valves are all located
check, the ECU briefly cycles the pump to verify op
within the HCU valve body and work in pairs to ei
eration. The HCU solenoids are checked continu
ously. ther increase, hold, or decrease apply pressure as
If an ABS component exhibits a fault during ini needed in the individual control channels.
tialization, the ECU illuminates the amber warning The solenoid valves are not static during antilock
light and registers a fault code in the microprocessor braking. They are cycled continuously to modulate
memory. pressure. Solenoid cycle time in antilock mode can be
measured in milliseconds.
ABS OPERATION IN NORMAL BRAKING MODE
The ECU monitors wheel speed sensor inputs con HCU SOLENOID WALWE OPERATION
tinuously while the vehicle is in motion. However,
Normal Braking
the ECU will not activate any ABS components as
long as sensor inputs and the acceleration switch in During normal braking, the HCU solenoid valves
dicate normal braking. and pump are not activated. The master cylinder and
During normal braking, the master cylinder, power power booster operate the same as a vehicle without
booster and wheel brake units all function as they an ABS brake system.
would in a vehicle without ABS. The HCU compo
nents are not activated. Antilock Pressure Modulation
Solenoid valve pressure modulation occurs in three
A B S OPERATION IN ANTILOCK BRAKING MODE stages which are: pressure increase, pressure hold,
The purpose of the antilock system is to prevent and pressure decrease. The valves are all contained
wheel lockup during periods of high wheel slip. Pre in the valve body portion of the HCU.
venting lockup helps maintain vehicle braking action
and steering control. Pressure Decrease
The antilock ECU activates the system whenever The outlet valve is opened and the inlet valve is
sensor signals indicate periods of high wheel slip. closed during the pressure decrease cycle (Fig. 11).
High wheel slip can be described as the point where A pressure decrease cycle is initiated when speed
wheel rotation begins approaching zero (or lockup) sensor signals indicate high wheel slip at one or
during braking. Periods of high wheel slip occur more wheels. At this point, the ECU opens the outlet
when brake stops involve high pedal pressure and valve. Opening the outlet valve also opens the hy
rate of vehicle deceleration. draulic return circuit to the master cylinder reser-
J ANTILOCK BRAKE SYSTEM OPERATION i - 53
L O W PRESSURE RESERVOIR PEDAL VACUUM

HOSES TRAVEL POWER
PUMP/MOTOR ASSEMBLY SENSOR BRAKE
LF. R.F. R.R. LR.

J9205-10
WHEEL WHEEL WHEEL WHEEL
Fig. 10 Three-Channel ABS Hydraulic Control Circuit

voir. Fluid pressure is allowed to bleed off (decrease)
as needed to prevent wheel lock. FLUID I N L E T FLUID O U T L E T
{FROM RESERVOIR) {TO RESERVOIR)
Once the period of high wheel slip has ended, the
ECU closes the outlet valve and begins a pressure in
OUTLET
crease or hold cycle as needed. TO
WHEEL
Pressure Hold BRAKE
Both solenoid valves are closed in the pressure hold

HCU
cycle (Fig. 12). Fluid apply pressure in the control VALVE
channel is maintained at a constant rate. The ECU BODY
maintains the hold cycle until sensor inputs indicate
a pressure change is necessary. OUTLET
VALVE
Pressure Increase
The inlet valve is open and the outlet valve is INLET
closed during the pressure increase cycle (Fig. 13). VALVE
The pressure increase cycle is used to counteract un
equal wheel speeds. This cycle controls reapplication | HIGH PRESSURE
of fluid apply pressure after a pressure decrease cy I L O W PRESSURE
cle.
J92Q5-14
HCU PUMP AND PEDAL TRAVEL SENSOR

Fig. 11 Solenoid Valves In Pressure Decrease Cycle
OPERATION
The HCU pump has two functions during antilock plunger is actuated by movement of the booster dia
braking. First, the pump supplies the extra volume phragm plate. The sensor has a total of seven pedal
of fluid needed. And second, the pump maintains positions, six of which are monitored. The six pedal
brake pedal height. The fluid source for the pump is positions monitored range from full release to full ap
the master cylinder reservoir. The reservoir and ply. Each pedal position (toward full apply), gener
HCU are interconnected by hoses. ates an increasing degree of electrical resistance in
The pump motor is activated by the ECU. How the sensor.
ever, the signal to run the pump actually comes from The ECU continuously monitors electrical resis
the pedal travel sensor. tance at the pedal travel sensor. The ECU activates
The pedal travel sensor is mounted in the forward the pump whenever sensor electrical resistance in
face of the brake booster (Fig. 14). The sensor creases during ABS mode braking.
5 - 54 ANTILOCK BRAKE SYSTEM OPERATION J
cylinder reservoir by hoses. During antilock braking,
FLUID I N L E T FLUID O U T L E T
(FROM RESERVOIR) (TO RESERVOIR) the additional volume of fluid needed is drawn by the
pump from the reservoir.
OUTLET
TO
WHEEL PEDAL
BRAKE TRAVEL
SENSOR
HCU
VALVE
BODY BRAKE
BOOSTER
OUTLET
VALVE
INLET SENSOR
COLOR CODED
VALVE PLUNGER J9205-15
CAP
HIGH P R E S S U R E
Fig. 14 Pedal Travel Sensor Actuation
CONSTANT PRESSURE
WHEEL SPEED SENSOR OPERATION
LOW PRESSURE
Wheel speed input signals are generated by a sen
J9205-13 sor and tone ring at each wheel. The sensors, which
are connected directly to the ECU, are mounted on
Fig. 12 Solenoid Valves In Pressure Hold Cycle brackets attached to the front steering knuckles and
FLUID I N L E T FLUID O U T L E T
rear brake support plates.
(FROM RESERVOIR) (TO RESERVOIR) The sensor triggering devices are the tone rings
which are similar in appearance to gears. The tone
OUTLET
TO rings are located on the outboard end of each front/
WHEEL rear axle shaft. The speed sensors generate a signal
BRAKE
whenever a tone ring tooth rotates past the sensor
pickup face.
The wheel speed sensors provide the input signal to
HCU the ECU. If input signals indicate ABS mode brak
VALVE
BODY ing, the ECU causes the HCU solenoids to decrease,
hold, or increase fluid apply pressure as needed.
The HCU solenoid valves are activated only when
OUTLET wheel speed input signals indicate that a wheel is
INLET VALVE
approaching a high slip, or lockup condition. At this
VALVE
point, the ECU will cycle the appropriate wheel con
trol channel solenoid valves to prevent slip or lockup.
HIGH P R E S S U R E
The wheel sensors provide speed signals whenever
the vehicle wheels are rotating. The ECU examines
LOW PRESSURE
these signals for degree of deceleration and wheel
slip. If signals indicate normal braking, the solenoid
J9205-12
valves are not activated. However, when incoming
Fig. 13 Solenoid Valves In Pressure increase Cycle signals indicate the approach of wheel slip, or lockup,
the ECU cycles the solenoid valves as needed.
At the start of antilock braking, pedal height will
decrease as the volume of fluid in the master cylin ACCELERATION SWITCH OPERATION
der is used up. When pedal height drops a predeter The ECU monitors the acceleration switch at all
mined amount, the pedal travel sensor will signal times. The switch assembly contains three mercury
the ECU to run the pump. At this point, the pump is switches that monitor vehicle ride height and decel
activated to supply the extra fluid volume and re eration rates (G-force). Sudden, rapid changes in ve
store pedal height at the same time. hicle and wheel deceleration rate, triggers the switch
The pump does not run continuously. It cycles on/ sending a signal to the ECU. The switch assembly
off according to signals from the travel sensor and provides three deceleration rates; two for forward
ECU. The pump is connected directly to the master braking and one for rearward braking.
J ANTILOCK B R A K E S Y S T E M OPERATION 5 - 55
ECU O P E R A T I O N pressure decrease, hold and increase phases to retard

The antilock ECU controls all phases of antilock and prevent wheel lock during periods of high wheel
operation. It monitors and processes input signals slip.
from all of the system sensors. Solenoid valve operation is selective. The solenoid
It is the ECU that activates the solenoid valves to valves may not be cycled simultaneously, nor are
modulate apply pressure during antilock braking. they all cycled in the same pressure modulation
The ECU program is able to determine which wheel phase at the same time. The ECU cycles the valves
control channel requires modulation and which fluid in each control channel as needed. For example, sen
pressure modulation cycle to use. sor inputs may indicate that only the leftfrontwheel
The ECU cycles the solenoid valves through the requires modulation during a period of high slip.
5 - 56 ABS COMPONENT SERVICE J
ABS COMPONENT SERVICE
INDEX
page page
Acceleration Sensor Installation . . . . . . . . . . . . . . 61 HCU R e m o v a l - Y J 63
Acceleration Sensor Removal 60 Importance of Clean Brake Fluid 56
Combination Valve Replacement—XJ 63 Master Cylinder Installation 59
Combination Valve Replacement—YJ . 64 Master Cylinder Removal 59
Component Serviceability . . . . . . . . . . . . . . . . . . . 56 Pedal Travel Sensor Service . . . . . . . . . . . . . . . . 59
Correct Fluid Level 56
Power Brake Booster Installation . 60
E C U Replacement—XJ 61
E C U Replacement—YJ 61 Power Brake Booster Removal 59
Front Wheel Sensor Installation . . . . . . . . . . . . . . 57 Rear Wheel Sensor Installation 58
Front Wheel Sensor Removal 57 Rear Wheel Sensor Removal 58
HCU Installation-XJ . . . . . . . . . . . . . . . . . . . . . . 62 Recommended Brake Fluid 56
HCU Installation-YJ 63 Specifications . 56
HCU Removal-XJ . . . . . . . . . . . . ... 62 Wheel Sensor Air Gap Adjustment . . . . . . . . . . . 56
COMPONENT SERVICEABILITY meeting the SAE and DOT standards, reclaimed

The ABS components are serviced as assemblies fluid, or fluid from open containers.
(Fig. 1); they are not repairable. The following ABS
components can be replaced separately: CORRECT FLUID LEVEL
• center feed master cylinder Correct brake fluid level is marked on the driver
• master cylinder-to-booster seal side of the master cylinder reservoir (Fig. 2).
• power brake booster (includes matched pedal Preferred fluid level is to the MAX indicator mark.
travel sensor) Acceptable fluid level is between the MAX and MIN
• booster check valve and grommet marks.
• pedal travel sensor and select fit caps If fluid level is at or below the MIN mark, the
brake hydraulic system should be checked for leaks.
• combination valve
• HCU and pump motor assembly CAUTION: Clean the reservoir caps and exterior
• ECU thoroughly before checking fluid level. Do not allow
• acceleration sensor any dirt or foreign material to enter the reservoir
• wheel sensors while checking fluid level. Such materials can inter
• system wire harnesses fere with solenoid valve operation causing an A B S
The axle shaft tone wheels are not serviceable. If a malfunction.
tone wheel becomes damaged, it will be necessary to
replace the axle shaft, or disc brake rotor and hub
assembly on 2-wheel drive models. IMPORTANCE OF CLEAN BRAKE FLUID
The wheel brake components such as the calipers, The antilock system brake fluid must be kept clean
brakeshoes, wheel cylinders, rotors and drums are all and uncontaminated. Foreign material in the fluid,
serviced the same as standard brake system compo or non-recommended fluids will cause system mal
nents. functions.
Clean the reservoir and caps thoroughly before
SPECIFICATIONS
checking level or adding fluid. Cap open lines and
The brake size and torque specifications for stan hoses during service to prevent dirt entry.
Dirt or foreign material entering the ABS hydrau
dard and ABS brake systems are located at the end
lic system through the reservoir opening will circu
of this section.
late within the system. The result will be poor brake
RECOMMENDED BRAKE FLUID performance and possible component failure. Use
clean, fresh fluid only to top off, or refill the system.
Recommended brake fluid for the Jeep ABS system
is Mopar DOT 3 brake fluid. If Mopar fluid is not W H E E L S E N S O R A I R GAP ADJUSTMENT
readily available, a top quality fluid meeting SAE Only rear sensor air gap is adjustable. The front
J1703 and DOT 3 standards can be used. sensors are fixed and cannot be adjusted.
Brake fluid used in the ABS system must meet the A rear sensor air gap adjustment is only
SAE and DOT quality standards and be exception needed when reinstalling an original sensor. Re
ally clean. Never use substandard fluid, fluid not placement sensors have an air gap spacer at-
J ABS COMPONENT SERVICE 5 - 57
RIGHT
FRONT
BRAKE LINE
POWER
BRAKE
BOOSTER
FRONT
HYDRAULIC
AXLE
CONTROL
HARNESS
UNIT
(HCU)
T O HCU T O HCU
REAR REAR FRONT
BRAKE LINE CIRCUIT CIRCUIT J9205-24
Fig. 1 ABS Hydraulic Component Locations—XJ

RESERVOIR, MASTER Front sensor air gap can only be checked. Air gap
CAPS CYLINDER should be 0.040 to 1.3 mm (0.0157 to 0.051 in.). If
RESERVOIR
FILL front sensor air gap is incorrect, the sensor is either
LEVEL
INDICATORS
loose, or damaged.
FRONT WHEEL SENSOR REMOVAL

(1) Raise vehicle and turn wheel outward for eas
ier access to sensor.
(2) Remove sensor wire from mounting brackets.
(3) Clean sensor and surrounding area before re
moval.
(4) Remove bolt attaching sensor to steering
knuckle and remove sensor.
(5) Unseat grommet retaining sensor wire in wheel
house panel.
(6) In engine compartment, disconnect sensor wire
Fig. 2 Reservoir Fluid Level Indicators connector at harness plug. Then remove sensor and
tached to the sensor pickup face. The spacer wire.
establishes correct air gap when pressed against
the tone ring during installation. As the tone FRONT WHEEL SENSOR INSTALLATION
ring rotates, it peels the spacer off the sensor to (1) Apply Mopar Lock N ' Seal or Loctite 242 to
create the required air gap. bolt that attaches sensor to steering knuckle. Use
Preferred rear sensor air gap is 1.1 mm (0.043 in.). new sensor bolt if original bolt is worn or damaged.
Acceptable air gap range is 0.92 to 1.275 mm (0.036 (2) Position sensor on steering knuckle. Seat sen
to 0.050 in.). sor locating tab in hole in knuckle and install sensor
Front sensor air gap is not adjustable. The front attaching bolt finger tight.
sensors are fixed in position and cannot be adjusted. (3) Tighten sensor bolt to 14 Nnn (11 ft. lbs.)
torque.
i - 18 ABS COMPONENT SERVICE J
(4) Attach sensor wire to steering knuckle bracket

with grommets on sensor wire.
(5) Route sensor wire forward and behind shock
absorber. Then attach sensor wire to spring seat
bracket with grommets on sensor wire.
(6) Route sensor wire to outer sill bracket. Remove
all twists or kinks from wire.
(7) Attach sensor wire to sill bracket with grom
met. Be sure wire is free of twists and kinks.
(8) Verify sensor wire routing. Wire should loop
forward and above sill bracket. Loose end of wire
should be below sill bracket and towards brake hose. Fig. 4 Rear Sensor Connections—XJ
(9) Seat sensor wire grommet in body panel and (7) Remove bolt attaching sensor to bracket and
clip wire to brake line at grommet location. remove sensor.
(10) Connect sensor wire to harness in engine com
partment. REAR W H E E L SENSOR INSTALLATION
(1) Insert sensor wire through support plate hole
REAR WHEEL SENSOR REMOVAL and seat sensor grommet in support plate.
(1) On XJ models, if separate connectors are not (2) Apply Mopar Lock N ' Seal or Loctite 242 to
used to attach sensor harness to each sensor wire, original sensor bolt. Use new bolt if original is worn
proceed as follows: or damaged.
(a) Raise and fold rear seat forward for access to (3) Install sensor bolt finger tight only at this
rear sensor connectors (Fig. 3). time.
(b) Disconnect sensors at rear harness connec (4) Set sensor air gap as follows:
tors. (a) If original sensor is being installed, remove
(c) Push sensor grommets and sensor wires any remaining pieces of cardboard spacer from sen
through floorpan. sor pickup face. Then adjust air gap to preferred
ACCELERATION setting of 1.1 mm (0.043 in.) with brass feeler
gauge (Fig. 5). Tighten sensor bolt to 11 N»m (11 ft.
lbs.) torque.
(b) If new sensor is being installed, push card
board spacer on sensor face (Fig. 6) against tone
ring. Then tighten sensor bolt to 8 N*m (6 ft. lbs.)
SENSOR torque. Correct air gap will be established as tone
MOUNTING ring rotates and peels spacer off sensor face.
BRACKET
(c) Verify sensor air gap adjustment. If adjust
ment changed after tightening bolt, readjust sensor
air gap as needed.
WHEEL
SPEED
SENSOR
BRASS
FEELER
GAUGE
TO L R . WHEEL R.R. W H E E L
SENSOR SENSOR J9205-19
Fig. 3 Rear Sensor Connections—MJ

(2) Raise vehicle. Fig. 5 Setting Air Gap On Original Rear Sensor
(3) Disconnect sensor wires at rear axle connectors. (5) On YJ, connect rear sensor wires to connectors
(4) Remove wheel and brake drum. at axle. On XJ, route sensor wires to rear seat area.
(5) Remove clips securing sensor wires to brake (6) Feed sensor wires through floorpan access hole
lines or rear axle and rear brake hose. and seat sensor grommets in floorpan.
(6) Unseat sensor support plate grommet.
ABS COMPONENT SERVICE 5 - 59
J
(5) Install and tighten master cylinder attaching
nuts to 34 N»m (25 ft. lbs.) torque.
(6) Connect brakelines to master cylinder.
(7) Install combination valve, if removed and in
stall bolt that secures valve bracket to master cylin
der.
(8) Connect sensor wires.
(9) Fill reservoir and bleed brakes. Refer to proce
dure in this section.
(10) Install air cleaner and hoses.
PEDAL TRAVEL SENSOR SERVICE

CAUTION: T h e pedal travel sensor and booster
must form a matched set. T h e cap on the sensor
J9205-35
plunger and booster shell are color coded for iden
Fig. 6 New Rear Sensor With Air Gap Spacer tification, and to ensure they are used as matched
sets. B e sure the color of the sensor cap and the
(7) Verify that rear sensor wire are secured to rear color dot on the booster shell are the same before
brake hose and axle with clips. Verify that wire is installation. Refer to the Sensor Replacement infor
clear of rotating components. mation before installing a new or original sensor.
(8) Install brake drum and wheel.
(9) Lower vehicle.
(10) On XJ, connect sensor wire to harness connec PEDAL TRAVEL SENSOR REMOVAL
tor. Then reposition carpet and fold rear seat down. (1) Disconnect wires at sensor.
(2) Pump brake pedal to exhaust all vacuum from
M A S T E R CYLINDER REMOVAL booster.
(1) Disconnect pedal travel sensor wires. (3) Unseat sensor retaining ring.
(2) Remove air cleaner and hoses on XJ models. (4) Remove sensor from booster (Fig. 7).
(3) Remove clamps that secure reservoir hoses to
PEDAL TRAVEL SENSOR REPLACEMENT
HCU pipes.
A new pedal travel sensor is supplied with four dif
(4) Position small drain container under master
ferent color caps. The caps are color coded to ease
cylinder reservoir. Remove reservoir hoses from HCU
matching them with the color code dot on the booster
pipes and allow fluid to drain into container before
shell.
removing reservoir. Discard fluid drained from reser
Compare the color of the new sensor cap and the
voir. color dot on the booster shell. If the colors match,
(5) Pump brake pedal to exhaust all vacuum from proceed with sensor installation. However, if the col
power brake booster. ors do not match, select and install the correct color
(6) Disconnect necessary brakelines at master cyl cap on the sensor plunger before proceeding.
inder and combination valve. Also remove combina
tion valve bracket bolt. PEDAL TRAVEL SENSOR INSTALLATION
(7) Remove nuts attaching master cylinder to (1) Check color dot on face of brake booster. Then
booster mounting studs. check color of cap on sensor plunger. If colors match,
(8) Remove master cylinder. Pull cylinder forward proceed with installation. If colors do not match, in
and off studs. Then work cylinder past combination stall correct color cap on end of plunger.
valve, brakelines, pedal travel sensor and out of en (2) Install O-ring on sensor.
gine compartment. (3) Install sensor retaining ring on booster flange.
(4) Insert sensor in retaining ring and booster.
MASTER CYLINDER INSTALLATION (5) Verify that retaining ring is properly engaged
(1) If new master cylinder is being installed, bleed in sensor and that sensor is seated in booster.
cylinder on bench before installing it in vehicle. (6) Connect wires to sensor.
(2) Work master cylinder into position and install (7) Check sensor operation with DRB II scan tool.
it in booster. Be sure cylinder is properly seated on
booster studs. Also be sure booster-to-cylinder seal is POWER BRAKE BOOSTER REMOVAL
not displaced during installation. (1) Pump brake pedal until all vacuum is ex
(3) Connect reservoir hoses to HCU pipes. hausted from power brake booster.
(4) Verify that master cylinder and booster are (2) Disconnect pedal travel sensor.
properly connected. (3) Remove air cleaner and hoses.
5 - 60 ABS COMPONENT SERVICE J
PLUNGER CAP RETAINING PEDAL (2) In passenger compartment, install booster at
(COLOR CODED T O MATCH RING TRAVEL taching nuts on mounting studs. Tighten attaching
*j BOOSTER COLOR DOT) / SENSOR
nuts to 41 Nnn (30 ft. lbs.) torque.
(3) Install seal on master cylinder. Seal is slight
interference fit to help hold it in place.
CAUTION: T h e pedal travel sensor and booster

must form a matched set. T h e cap on the sensor
plunger and the color dot on the booster shell are
color coded for identification, and to ensure they
are used as matched sets. Be sure the color on the
sensor cap and booster shell are the s a m e before
installation. Refer to the Sensor Replacement infor
POWER
BRAKE
mation before installing a new or original sensor.
BOOSTER
(4) If new pedal travel sensor is being installed in
Fig. 7 Pedal Travel Sensor Mounting original booster, compare color dot on booster shell
(4) Remove clamps that secure reservoir hoses to with color of cap on sensor (Fig. 9). If both are same
HCU pipes. Then remove hoses from pipes. color, proceed with installation. However, if colors do
(5) Disconnect brakelines at master cylinder. not match, select correct color cap from kit supplied
with new sensor and install it on end of sensor
(6) Remove combination valve bracket bolt if nec
plunger.
essary.
(5) Install O-ring on pedal travel sensor.
(7) Remove nuts attaching master cylinder to
(6) Install sensor retaining ring on booster flange.
booster mounting studs.
Be sure retaining ring is firmly seated.
(8) Remove master cylinder. Pull cylinder forward (7) Insert sensor into booster. Be sure sensor is
and off studs. Then work cylinder past combination fully seated and engaged in retaining ring.
valve, brakelines, pedal travel sensor and out of en (8) Connect booster push rod to brake pedal.
gine compartment. (9) Attach vacuum hose to booster check valve.
(9) Disconnect vacuum hose at booster check valve. (10) Install master cylinder on booster. Tighten
(10) Disconnect booster push rod from brake pedal. cylinder attaching nuts to 25-30 Nmi (220-267 in.
(11) Remove nuts attaching booster to passenger lbs.) torque.
compartment side of dash panel. (11) Connect brakelines to master cylinder.
(12) Slide booster forward and work it out of en (12) Install combination valve bracket bolt if re
gine compartment. moved.
(13) Connect reservoir hoses to HCU pipes.
POWER BRAKE BOOSTER INSTALLATION (14) Connect sensor wires.
(1) Position booster on dash panel. Align booster
(15) Bleed brakes. Refer to procedure in this sec
mounting studs with holes in panel and seat booster
tion.
(Fig. 8).
(16) Install air cleaner and hoses.
BOOSTER
PUSH
DASH MOUNTING PEDAL
NUTS
BOOSTER NUTS TRAVEL
SENSOR
BRAKE
BOOSTER
SENSOR
COLOR CODED
BOOSTER PLUNGER J9205-15
CAP
MOUNTING
WITH ABS BOLTS
Fig. 9 Booster Push Rod And Pedal Travel Sensor
J9305-81
ACCELERATION SENSOR REMOVAL
Fig. 8 Booster Attachment At Dash Panel—YJ (1) On XJ models, tilt rear seat assembly forward
Shown for access to sensor (Fig. 10).
J A B S COMPONENT S E R V I C E 5 - 61
(2) On YJ models, move driver seat forward or (2) Position sensor in mounting bracket (Fig. 10).
rearward for access to sensor (Fig. 10). (3) Install and tighten sensor attaching screws to
(3) Disconnect sensor harness (Fig. 10). 2-4 N*m (17-32 in. lbs.) torque.
(4) On XJ models, remove screws attaching sensor (4) Connect harness to sensor. Be sure harness
to bracket. Then remove sensor. connecter is firmly seated.
(5) On YJ models, remove screws attaching sensor (5) Move seat back to normal position.
bracket to floorpan. Then remove sensor from
bracket. ECU REPLACEMENT—XJ
ACCELERATION ECU Removal
SENSOR
(1) Turn ignition key to Off position.
(2) Remove screws attaching ECU to mounting
bracket (Fig. 11).
(3) Disconnect ECU wiring harness.
SENSOR (4) Remove ECU.
REAR S E A T
MOUNTING
CROSSMEMBER
BRACKET IGNITION STEERING
SWITCH COLUMN
SUPPORT
XJ
MODELS
TO
SENSOR T~ R.R. W H E E L
HARNESS FLOORPAN SENSOR
STOPLIGHT
SWITCH
SECURITY
ECU ANTILOCK STEERING
ALARM
BRACKET ECU COLUMN
MODULE
J9205-20
Fig. 11 Antilock ECU Mounting-XJ

ECU Installation
(1) If new ECU is being installed, transfer mount
ing bracket to new ECU.
SENSOR (2) Tighten ECU-to-mounting bracket screws to
HARNESS AND
CONNECTOR 8-13 N*m (75-115 in. lbs.) torque.
(3) Connect wire harness to ECU.
J9305-86 (4) Position and install ECU.
(5) Tighten ECU attaching nuts to 10-14 N*m (85-
Fig. 10 Acceleration Sensor Mounting 125 in. lbs.) torque.
ACCELERATION SENSOR INSTALLATION ECU REPLACEMENT-YJ
(1) Note position of locating arrow on sensor. Sen The antilock electronic control unit (ECU) is at
sor must be positioned so arrow faces forward. tached to the dash panel inside the passenger com
CAUTION: T h e sensor mercury switch will not func
partment. It is positioned just above the heater/air
tion properly if the sensor i s mispositioned. Verify
conditioning plenum housing, in line with the glove
that the sensor locating arrow i s pointing to the
box (Fig. 12).
front of the vehicle.
5 - 62 ABS COMPONENT SERVICE
The ECU is attached to the dash panel by bolts HCU HCU

and nuts that are accessible from the engine com PUMP M O T O R
HARNESS AND
partment. The fasteners are located just to the right CONNECTORS
of the battery.
On models with air conditioning, it will be neces
sary to remove the air conditioning fascia panel and
ducts for access to the ECU and harness connecter.
T O DASH PANEL
GROMMET
ANTILOCK
-LIS ECU HCU
SOLENOID
HARNESS
AND
CONNECTORS J9205-21
Fig. 14 HCU Wire Harness Connections

(7) Move HCU harness and air cleaner hose pipe
aside for access to HCU bracket nuts.
(8) Remove single bolt and two nuts attaching
ABS HCU to mounting bracket on inner fender panel
HARNESS (Fig. 15).
CONNECTOR J9305-87
(9) Remove HCU. Lift HCU up and off mounting
Fig. 12 ECU Location-YJ bracket studs. Then work HCU past brakelines and
master cylinder to remove it.
HCU REMOVAL-XJ
(1) Remove air cleaner. HYDRAULIC
(2) Remove clamp that secures air cleaner hose CONTROL
U N I T (HCU)
and pipe to fender apron (Fig. 13).
(3) Position suitable size fluid drain container un
der master cylinder reservoir hoses. Disconnect reser
voir hoses from HCU and drain fluid into container.
INNER
Discard old fluid and remove reservoir. FENDER
(4) Disconnect pump motor and solenoid harness PANEL
wires at HCU (Fig. 14).
AIR HCU
CLEANER HARNESS HCU BODY
HOUSING CONNECTOR MOUNTING
BRACKET
CLAMP
J92Q5-22
Fig. 15 HCU Mounting-XJ

HCU INSTALLATION—XJ
HOSE
(1) Connect master cylinder reservoir hoses to
PIPE HCU pipes.
(2) Position HCU assembly on mounting bracket
HCU
HARNESS and install attaching nuts.
CONNECTOR (3) Connect hydraulic lines to HCU (Fig. 16). Line
J92Q5-27 fitting nuts and bosses on valve body ports are color
coded. Be sure lines are properly connected.
Fig. 13 Air Cleaner And Harness Connector (4) Connect HCU harness wires to HCU.
Location—XJ (5) Check routing of HCU lines/hoses. Be sure
(5) Mark or tag HCU hydraulic lines for assembly lines are not kinked and are clear of engine compo
reference. nents.
(6) Disconnect hydraulic lines at HCU. (6) Fill master cylinder reservoir with Mopar DOT
3 brake fluid or equivalent.
A I S COMPONENT SERVICE 5 - S3
J
RESERVOIR INLET FROM MASTER
PIPES COMBINATION CYLINDER
VALVE
AND
BOOSTER
TO
REAR
WHEELS HCU
VALVE
BODY
TO TO
LEFT RIGHT
HCU M O U N T I N G
FRONT FRONT
BRACKET (UNDER APRON)
WHEEL WHEEL J9205-23 J9305-78
Fig. 16 HCU Hydraulic Line Connections Fig. 17 HCU Mounting- YJ

(7) Bleed brake system. (3) Disconnect pedal travel sensor harness connec
(8) Install air cleaner and hoses. Secure air cleaner tor and move harness wires aside for working access
hose pipe to fender apron with clamp. if necessary.
(9) Check brake pedal action. Bleed brakes again if (4) Disconnect pressure differential switch wires at
pedal is not firm (feels soft/spongy). valve.
(5) Disconnect hydraulic lines at valve and remove
HCU REMOVAL—YJ valve from vehicle.
(1) Place shop towels or small container under (6) Connect hydraulic lines to valve.
master cylinder reservoir hoses. (7) Position valve bracket on master cylinder and
(2) Disconnect master cylinder reservoir hoses at install bracket attaching bolt.
HCU.
(8) Reconnect pressure differential switch and
(3) Disconnect all sensor and harness wires at
pedal travel sensor wires.
HCU.
(9) Bleed brake system. Refer to procedure in this
(4) Disconnect brakelines at HCU (Fig. 17). Mark
or tag lines for installation reference. section.
(5) Remove bolt and nuts attaching HCU mount
ing bracket to fender apron and remove HCU.
HCU INSTALLATION-YJ
(1) Position HCU on fender apron and install at
taching bolts/nuts.
(2) Connect brakelines to HCU.
(3) Connect harness and sensor wires to HCU.
(4) Connect master cylinder reservoir hoses to
HCU.
(5) Fill and bleed brake system.
COMBINATION V A L V E R E P L A C E M E N T - X J
The combination valve is not a repairable compo
AND VALVE COMBINATION
nent. The valve is serviced as an assembly whenever
HARNESS BRACKET VALVE J9205-25
diagnosis indicates replacement is necessary.
(1) Remove air cleaner housing for access to valve, Fig. 18 Combination Valve Mounting—XJ
if necessary.
(2) Remove bolt attached valve to master cylinder
(Fig. 18).
5 - 64 ABS COMPONENT SERVICE 4
COMBINATION VALVE REPLACEMENT-YJ (5) Start all brakelines in combination valve by

The combination valve mounting bracket is perma hand. Tighten line fittings just enough to prevent
nently attached to the valve. The bracket and valve leaks.
are serviced as an assembly. (6) Position valve mounting bracket on studs.
(1) Disconnect harness wires from combination (7) Install and tighten nuts that attach combina
valve switch. tion valve bracket to studs on power brake booster.
(2) Disconnect brakelines attached to combination (8) Connect wires to combination valve switch.
valve. (9) Fill and bleed brake system.
(3) Remove nuts attaching combination valve
(10) Final-tighten brakeline fittings to 18-23 Nnn
bracket to master cylinder mounting studs (Fig. 17).
(4) Remove valve and bracket as assembly. (160-210 in. lbs.) torque after bleeding brakes.
ABS COMPONENT SERVICE 5 - 65
SPECIFICATIONS
BRAKE TORQUE SPECIFICATIONS
COMPONENT SERVICE SET-TO T O R Q U E

Acceleration sensor bracket screws 1-2 N m (13-18 in. lbs.)
Acceleration sensor screws 8-9 N m (71-83 in. lbs.)
Brakeline fitting at master cylinder 20 N m (180 in. lbs.)
Brakeline fitting at combination valve: 18-24 N m (160-210 in. lbs.)
Brakeline fitting at wheel cylinder 18 N-m (160 in. lbs.)
Brake pedal pivot bolt nuts:
Man. trans 2 7 N m (20 ft. lbs.)
Auto trans. 35 N m 2 6 ft. lbs.)
Front brakeltne-to-brake hose fitting 15-18 N m (130-160 in. lbs.)
Rear brake hose T-fitting retainer bolt 7-9 N m (60-80 in. lbs.)
Rear brake support plate bolts
XJ-YJ 43 N m (32 ft. lbs.)
Caliper anchor bracket bolts ( 2 W D models) 105 N m (77 ft. lbs.)
Caliper brake hose fitting bolt 24-38 N m (216-336 in. lbs.)
Caliper mounting bolts:
4 wheel drive XJ-YJ 10-20 N m (7-15 ft. lbs.)
2 wheel drive XJ 34-47 N m (25-35 ft. lbs.)
ECU bracket nuts 10-14 N-m (85-125 in. lbs.)
ECU harness connector bolt 10-14 N-m (85-125 in. lbs.)
ECU-to-bracket screws 8-13 N-m (75-115 in. lbs.)
HCU brakeline fittings 18-23 N-m (160-200 in. lbs.)
HCU mounting bracket bolt and nuts 10-13 (92-112 in. lbs.)
Master cylinder mounting stud nuts 13-25 N m (115-220 in. lbs.)
Power booster nuts 41 N-m (30 ft. lbs.)
Parking brake pedal assembly nuts/bolts:
YJ (nuts) 15 N-m (11 ft.. lbs.)
YJ bolts) 10 N-mi 77 ft.
ft. lbs.)
Wheel bearing nuts 237 N-m (175 ft. lbs.)
Wheel cylinder mounting bolts:
with model 4 4 axle 15-25 N-m (130-230 in. lbs.)
XJ-YJ 8-18 (6-13 ft. lbs.)
Wheel lug nuts
Wheel speed sensor adjusting bolt 14 N-m (11 ft. lbs.)
J9305-89
J CLUTCH 6 - 1
CLUTCH
CONTENTS
page page
C L U T C H DIAGNOSIS 4 GENERAL INFORMATION 1

CLUTCH SERVICE 11
GENERAL I I
CLUTCH COMPONENTS CLUTCH FLUID
A hydraulic clutch mechanism is used on Jeep Clutch system fluid level is checked at the clutch
models with manual transmission. Basic components master cylinder (Fig. 3).
consist of the disc, clutch cover, hydraulic concentric Correct clutch fluid level is to the indicator ring in
bearing and pilot bearing (Fig. 1). the cylinder reservoir (Fig. 4).
The clutch disc is a single, dry-type disc with cush The only fluid recommended for use in the clutch
ion springs in the hub. The clutch disc friction mate hydraulic system is Mopar Brake Fluid, or an equiv
rial is riveted to the hub. alent meeting SAE/DOT standards J1703 and DOT
The clutch cover is a diaphragm style with one- 3.
piece spring and multiple release fingers. Never use reclaimed brake fluid or fluid from
A 266 mm (10-1/2 in.) clutch is used for 4.0L en an unsealed container. In addition, do not use
gine applications. A 232 mm (9-1/4 in.) clutch is used fluid from a container that has been opened and
for 2.5L engine applications. allowed to stand for any length of time. Moisture
in the air can be absorbed by the fluid causing
CLUTCH HYDRAULIC LINKAGE dilution and loss of effectiveness.
The clutch hydraulic linkage consists of the clutch
master cylinder, hydraulic concentric bearing and GENERAL SERVICE INFORMATION
fluid lines (Fig. 2). The master cylinder fluid line is The hydraulic concentric bearing and fluid lines
equipped with a quick disconnect fitting. are serviced as an assembly. Neither the bearing or
The clutch master cylinder is mounted on the driv fluid lines can be disassembled for repair. The fluid
ers side of the dash panel adjacent to the brake mas lines are permanently attached and will leak if loos
ter cylinder and power booster. The cylinder is ened or if removal is attempted.
operated by a suspended type clutch pedal (Fig. 2). Nylon retaining straps are installed on the concen
The hydraulic concentric bearing is a unique de tric bearing during manufacture. The straps hold the
sign. It incorporates the release bearing and slave bearing piston in place during shipment and instal
cylinder in a single assembly. The bearing is perma lation. It is not necessary to cut or remove the straps
nently attached to the cylinder piston. The hydraulic after bearing installation. The straps are designed to
lines are permanently attached to the cylinder and disconnect the first time piston movement occurs.
bearing assembly and are not removable. The clutch master cylinder and lines are not re
The hydraulic concentric bearing completely encir pairable. If either the cylinder or line is leaking, or
cles the transmission input shaft. In operation, piston faulty, replace the cylinder as an assembly. The
movement causes the bearing to move in a linear clutch disc, cover and pilot bearing are also serviced
(straight line) direction. as assemblies.
6 - 2 CLUTCH
4 - C Y L 1 N D E R CLUTCH
COMPONENTS
CLUTCH H O U S I N G
CLUTCH
COVER
CLUTCH
DISC
PILOT
BEARING
SPACER
PLATE
PILOT RETAINING
BEARING NUT GROMMET J9106-4
Fig. 1 Clutch Components

CLUTCH 6 -3
J
BEARING LINE J9106-5 J 9
Fig. 2 Clutch Hydraulic Components Fig. 4 Reservoir Fluid Level Indicator Ring
6 -4 CLUTCH DIAGNOSIS J
CLUTCH DIAGNOSIS
INDEX
page page
Clutch Problem Causes 4 Inspection and Diagnosis Charts 5
General Diagnosis Information 4
GENERAL DIAGNOSIS INFORMATION Misalignment caused by excessive runout or warpage

Unless the cause of a clutch problem is extremely of any clutch component will cause grab, chatter and
obvious, accurate problem diagnosis will usually re improper clutch release.
quire a road test to confirm a problem. Component
inspection will then be required to determine the ac Flywheel Runout
tual problem cause. Check flywheel runout whenever misalignment is
During a road test, drive the vehicle at normal suspected. Flywheel runout should not exceed 0.08
speeds. Shift the transmission through all gear mm (0.003 in.). Measure runout at the outer edge of
ranges and observe clutch action. If chatter, grab, the flywheel face with a dial indicator. Mount the in
slip, or improper release is experienced, remove and dicator on a stud installed in place of one of the fly
inspect the clutch components. However, if the prob wheel bolts.
lem is noise or hard shifting, further diagnosis may Common causes of runout are:
be needed as the transmission or another driveline • heat warpage
component may be at fault. Careful observation dur • improper machining
ing the test will help narrow the problem area. • incorrect bolt tightening
CLUTCH PROBLEM CAUSES • improper seating on crankshaft flange shoulder
• foreign material on crankshaft flange
CONTAMINATION Cleanup of minor flywheel scoring should be per
Fluid contamination is a frequent cause of clutch formed with surface grinding equipment. Remove
malfunctions. Oil, water, or clutch fluid on the clutch only enough material to reduce scoring (approximate
contact surfaces will cause faulty operation. The ly 0.001 - 0.003 in.). Heavy stock removal is n o t r e c
usual result is chatter, slip and grab. o m m e n d e d . Replace the flywheel if scoring is severe
During inspection, note if any components are con and deeper than 0.076 mm (0.003 in.). Excessive
taminated with oil, hydraulic fluid, or water/road stock removal can result in flywheel cracking or
splash. warpage after installation; it can also weaken the
Oil contamination indicates a leak at either the flywheel and interfere with proper clutch release.
rear main seal or transmission input shaft. Oil leak Clean the crankshaft flange before mounting the
age produces a residue of oil on the housing interior flywheel. Dirt and grease on the flange surface may
and on the clutch cover and flywheel. Heat buildup cock the flywheel causing excessive runout. Use new
caused by slippage between the cover, disc and fly bolts when remounting a flywheel and secure the
wheel, can sometimes bake the oil residue onto the bolts with Mopar Lock And Seal. Tighten flywheel
components. The glaze-like residue ranges in color bolts to specified torque only. Overtightening can dis
from amber to black. tort the flywheel hub causing runout.
Road splash contamination means dirt/water is en
tering the clutch housing due to loose bolts, housing Clutch Cover And Disc Runout
cracks, or through hydraulic line openings. Driving Check the clutch disc before installation. Axial
through deep water puddles can force water/road (face) runout of a n e w disc should not exceed 0.50
splash into the housing through such openings. mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
Clutch fluid leaks are from loose or damaged con from the outer edge of the disc facing. Obtain an
centric bearing lines or connections. However, clutch other disc if runout is excessive.
fluid leaks will usually be noted and corrected before Check condition of the clutch before installation. A
severe contamination occurs. warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
CLUTCH MISALIGNMENT when handling the cover and disc. Impact can distort
Clutch components must be in proper alignment the cover, diaphragm spring, release fingers and the
with the crankshaft and transmission input shaft. hub of the clutch disc.
J C L U T C H DIAGNOSIS 6 - 5
Use an alignment tool when positioning the disc on Improper clutch cover bolt tightening can distort
the flywheel. The tool prevents accidental misalign the cover. The usual result is clutch grab, chatter
ment which could result in cover distortion and disc and rapid wear. Tighten the cover bolts as described
damage. in Clutch Service section.
A frequent cause of clutch cover distortion (and An improperly seated flywheel and/or clutch hous
consequent misalignment) is improper bolt tighten ing are additional causes of clutch failure. Improper
ing. To avoid warping the cover, the bolts must tight seating will produce misalignment and additional
ened alternately (diagonal pattern) and evenly (2-3 clutch problems.
threads at a time) to specified torque. The use of non-standard or low quality parts will
also lead to problems and wear. Use recommended
Clutch Housing Misalignment
factory quality parts to avoid comebacks.
Clutch housing alignment is important to proper
clutch operation. The housing maintains alignment
I N S P E C T I O N AND DIAGNOSIS C H A R T S
between the crankshaft and transmission input shaft.
The clutch inspection chart (Fig. 5) outlines items
Misalignment can cause clutch noise, incomplete re
to be checked before and during clutch installation.
lease and chatter. It can also result in premature
wear of the pilot bearing, cover release fingers and Use the chart as a check list to help avoid overlook
clutch disc. In severe cases, misalignment can also ing potential problern sources during service opera
cause premature wear of the transmission input tions.
shaft and shaft bearing. The diagnosis charts describe common clutch prob
Housing misalignment is generally caused by in lems, causes and correction. Fault conditions are
correct seating on the engine or transmission, loose listed at the top of each chart. Conditions, causes and
housing bolts, missing alignment dowels or housing corrective action are outlined in the indicated col
damage. Infrequently, misalignment may also be umns.
caused by housing mounting surfaces that are not The charts are provided as a convenient reference
parallel. when diagnosing faulty clutch operation.
INSTALLATION METHODS AND PARTS

USAGE
Distortion of clutch components during installation
and the use of non-standard components are addi
tional causes of clutch malfunction.
6 - 6 C L U T C H DIAGNOSIS
8 Check flywheel condition and runout. Scuff sand

flywheel face to remove glaze. Clean surface with
a wax and grease remover afterward. Replace
flywheel if severely scored, worn or cracked. Secure
flywheel with new bolts (if removed). Do not reuse
old bolts. Use Lock and Seal on bolts.
9 Check clutch housing bolts. Tighten if loose. Be sure

housing is fully seated on engine block. Also be sure
locating dowels are in place.
10 Check flywheel face runout if chatter or grab was

encountered. Runout should not exceed .08 mm
(.003 in.).
11 Tighten clutch cover bolts 2-3 threads at a time, alter

nately and evenly (in a diagonal pattern) to specified
torque. Failure to do so could warp the cover.
12 Check clutch cover. Replace if warped, cracked, bent.

Be sure cover is correct size and properly aligned
on disc and flywheel.
13 Check clutch cover diaphragm spring and release

fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with fac
tory clutch spring setting. Clutch problems will result.
14 Inspect concentric bearing hydraulic lines. Be sure

connections are tight and not cross threaded.
1 Make sure side of clutch disc marked "flywheel side" Replace bearing assembly o n l y if lines are loose, or
is toward flywheel. leaking.
2 Check flywheel bolt torque. If bolts are loose, 15 Transmission input shaft bearing will cause noise,
replace them. Use Mopar Lock and Seal to secure chatter, or improper release if damaged. Check con
new bolts. dition before installing transmission.
3 Check pilot bearing. Replace bearing if brinnelled, 16 Check input shaft seal if clutch cover and disc were
seized, or noisy. Lube bearing with wheel bearing oil covered. Replace seal if worn, or cut.
grease before installation.
17 Check concentric bearing mounting pin and retain
4 Check transmission input shaft. Clutch disc must slide ing nut. Never reuse old retaining nut. Use new part
freely on shaft splines. Lightly grease splines before only. Be sure pin is secure and in good condition.
installation. Replace shaft if splines or pilot bearing
hub are damaged. 18 Do not replace hydraulic concentric bearing unless
actually faulty. Replace bearing only if it leaks, is
5 Check crankshaft flange (if flywheel is removed). Be seized, or damaged.
sure flange is clean and flywheel bolt threads are
in good condition. 19 Inspect clutch housing. Be sure locating dowels are
in position and bolts are tight. Replace housing if
6 Check rear main seal if clutch disc and cover were cracked, or damaged, if clutch problems ocurred,
oil covered. Replace seal if necessary. check runout, to be sure housing is square with
flywheel and transmission input shaft.
7 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Also check 20 Check condition of pressure plate surface. Replace
runout of new disc. Runout should not exceed .5 mm clutch cover if plate surface is deeply scored,
{.02 in.). warped, worn, or cracked.
J9006-11
Fig. 5 Clutch Inspection Points

CLUTCH SLIPS
Condition Found Caus© Correction
1. Disc facing worn out a) Normal wear Replace clutch disc. Also replace
cover if spring is weak or pressure
b) Driver frequently "rides" plate surface is damaged.
(slips) clutch. Results in rapid
wear overheating.
c) Insufficient clutch cover

diaphragm spring tension.
2. Clutch disc facing a) Leak at rear main seal or at Replace leaking seals. Apply less
contaminated with oil, grease, transmission input shaft seal. grease to input shaft splines.
or clutch fluid. Replace concentric bearing only if
b) Excessive amount of grease actually leaking. Replace clutch disc
applied to input shaft splines. (do not clean and reuse). Clean
clutch cover and reuse only if cover
c) Leak from concentric bearing is in good condition.
or bearing hydraulic line
fittings.
3. Clutch is running partially Concentric bearing sticking-binding. Verify that bearing is actually
disengaged. Does not return to normal running binding, then replace bearing.
position.
4. Flywheel height incorrect. Flywheel surface improperly Replace flywheel.
machined. Too much stock removed
or surface is tapered.
5. Wrong disc or pressure plate Incorrect parts order or model Replace with correct parts.
installed. number. Compare old and new parts before
installation.
6. Clutch disc, cover and/or a) Rough handling (impact) bent Install new disc or cover as needed.
diaphragm spring, warped, cover, spring, or disc. Follow installation/tightening
distorted. instructions.
b) Incorrect bolt tightening
sequence and method caused
warped cover.
7. Facing on flywheel side of disc Flywheel surface scored and nicked. Reduce scores and nicks by sanding
torn, gouged, worn. or surface grinding. Replace
flywheel if scores-nicks are deeper
than .002-.004 inch.
8. Clutch disc facing burnt a) Frequent operation under high Scuff sand flywheel. Replace clutch
(charred). Flywheel and cover loads or hard acceleration cover and disc. Alert driver to
pressure plate surfaces heavily conditions. problem cause.
glazed.
b) Driver frequently "rides"
(slips) clutch. Results in rapid
wear and overheating of disc
and cover.
J9006-13
J
IMPROPER CLUTCH RELEASE

Condition F o u n d Cause Correction
1. Clutch disc warped. New disc not checked for axial Replace disc. Be sure runout of new
runout before installation. disc is less than .5 mm (.020 in.).
2. Clutch disc binds on input a) Clutch disc hub splines Clean, smooth and lubricate disc
shaft splines. damaged during installation. and shaft spines. Replace disc
and/or input shaft if splines are
b) Input shaft splines rough, severely damaged.
damaged.
c) Corrosion, rust formations on

splines of disc and input shaft.
3. Clutch disc rusted to flywheel Occurs in vehicles stored, or not Remove clutch cover and disc. Sand
and/or pressure plate. driven for extended periods rusted surfaces clean with 180 grit
of time. paper.
4. Clutch disc facing sticks to Vacuum may form in pockets over Drill 1/16 inch diameter hole
flywheel. rivet heads in clutch disc. Occurs as through rivets and scuff sand disc
clutch cools down after use. facing with 180 grit paper.
5. Clutch disc too thick. Wrong disc installed. Replace disc.
6. Pilot bearing seized. a) Bearing cocked during Lubricate and install new bearing.
installation. Check and correct any
misalignment.
b) Bearing defective.
c) Bearing not lubricated.
d) Clutch misalignment.
7. Clutch will not disengage a) Low fluid level in cutch master a) Top off cylinder and check for
properly. cylinder. leaks.
b) Air in clutch hydraulic system. b) Bleed and refill system.
c) Clutch cover loose. c) Tighten bolts.
d) Wrong clutch disc d) Install correct disc.
e) Disc bent, distorted during e) Replace disc.

installation.
f) Clutch cover diaphragm spring f) Replace cover.

bent or warped during
transmission installation.
g) Clutch disc installed g) Remove and reinstall disc

backwards. correctly. Be sure disc side
marked "to flywheel" is
actually toward flywheel.
I
J9006-14
CLUTCH GRAB/CHATTER
Condition Found Cause Correction
1. Clutch disc facing covered with a) Oil leak at rear main or input a) Correct leak and replace disc
oil, grease, or clutch fluid. shaft seal. (do not clean and reuse the
disc).
b) Too much grease applied to b) Apply lighter grease coating

splines or disc and input shaft. to splines and replace disc (do
not clean and reuse the disc).
c) Concentric bearing, line or c) Replace concentric bearing

fittings leaking fluid. and replace disc (do not clean
and reuse the disc).
2. Clutch disc and/or cover Incorrect or substandard parts. Replace disc and/or cover with
warped, or disc facings exhibit correct parts.
unusual wear or appear to be
wrong type.
3. Clutch master cylinder plunger a) Cylinder components worn or q) Overhaul or replace clutch
or concentric bearing corroded. master cylinder.
dragging-binding.
b) Concentric bearing is faulty. b) Replace the bearing.
4. No fault found with clutch a) Problem actually related to a) Further diagnosis required.
components. suspension or driveline Check engine/transmission
component. mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Engine related problem. b) Check EFI and igniton systems.

5. Partial engagement of clutch a) Clutch pressure plate position a) Replace clutch cover and disc.
disc (one side worn-opposite setting incorrect or modified.
side glazed and lightly worn). b) Replace clutch cover and disc.
b) Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
c) Clutch disc damaged or c) Replace disc.

distorted.
d) Clutch misalignment. d) Check alignment and runout of

flywheel, disc, or cover.
J9006-15
J
CLUTCH NOISE
Condition Found Cause Correction
1. Clutch components damaged Incorrect or sub-standard clutch Replace with parts of correct type
or worn out prematurely. parts. and quality.
2. Pilot bearing seized or a) Bearing cocked or scored a), b), c) Replace bearing. Be
bearing rollers are brinneled. during installation. sure it is properly seated and
b) Bearing not lubricated prior to lubricated before installing
installation. clutch.
c) Bearing defect.
d) Clutch misalignment. d) Check and correct

misalignment caused by
excessive runout of flywheel,
disc, or cover. Replace input
shaft if bearing hub is
damaged.
3. Loose components. Attaching bolts loose at flywheel, Tighten bolts to specified torque.
cover, or clutch housing. Replace any clutch bolts that are
damaged.
4. Components appear Frequent high load, full throttle Replace parts as needed. Alert
overheated. Hub of disc operation. driver to condition causes.
cracked or torsion damper
springs are distorted or
broken.
5. Contact surface of concentric a) Clutch cover incorrect, or a) Replace clutch cover and
bearing damaged. release fingers are bent or concentric bearing.
distorted causing damage.
b) Concentric bearing defect. b) Replace concentric bearing.
c) Concentric bearing misaligned. c) Check and correct runout of

clutch components. Also check
input shaft and bearing
condition. Replace shaft and
bearing if worn or damaged.
6. Concentric bearing is noisy. Concentric bearing defect. Replace concentric bearing.
7. Clutch pedal squeak. a) Pivot pin loose. Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
b) Pedal bushings worn out or and bushings with silicone base
cracked. lubricator chassis grease.
J9006-16
CLUTCH SERVICE 6 - 1 1
J
CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation 11 Clutch Pedai Removal . . . . . . . . . . . . . . . . . . . . . 16
Clutch Cover and Disc Removal 11 Clutch Safety Precautions 11
Clutch Fluid Level : 16 Flywheel Service 15
Clutch Housing Replacement 14 Hydraulic Concentric Bearing Replacement 13
Clutch Master Cylinder Installation 12 Hydraulic System Bleeding 16
Clutch Master Cylinder Removal 12
Pilot Bearing Replacement 12
Clutch Pedal Installation 16
CLUTCH SAFETY PRECAUTIONS C L U T C H COVER AND DISC I N S T A L L A T I O N

(1) Lightly scuff sand flywheel face with 120/180
WARNING: E X E R C I S E CARE WHEN SERVICING grit emery cloth. Then clean surface with a wax and
CLUTCH COMPONENTS. D U S T AND D I R T T H A T AC grease remover.
C U M U L A T E S ON CLUTCH P A R T S DURING NORMAL (2) Lubricate pilot bearing with Mopar high tem
U S E MAY CONTAIN A S B E S T O S F I B E R S . BREATHING perature bearing grease.
EXCESSIVE CONCENTRATIONS OF T H E S E F I B E R S (3) Check runout and free operation of new clutch
CAN CAUSE S E R I O U S BODILY HARM. W E A R A R E S disc as follows:
PIRATOR W H E N CLEANING CLUTCH COMPONENTS (a) Slide disc onto transmission input shaft
AND NEVER CLEAN CLUTCH COMPONENTS W I T H splines. Disc should slide freely on splines.
C O M P R E S S E D AIR OR W I T H A DRY B R U S H . U S E A (b) Leave disc on shaft and check face runout
VACUUM CLEANER SPECIFICALLY DESIGNED F O R with dial indicator. Check runout at disc hub and
REMOVING A S B E S T O S F I B E R S AND D U S T . IF A VAC about 6 mm (1/4 in.) from outer edge of facing.
UUM C L E A N E R I S NOT AVAILABLE, CLEAN T H E (c) Face runout should not exceed 0.5 mm (0.020
P A R T S W I T H W A T E R DAMPENED SHOP RAGS. DO in.). Obtain another clutch disc if runout exceeds
NOT C R E A T E D U S T B Y SANDING A C L U T C H DISC. IF this limit.
T H E DISC FRICTION S U R F A C E IS DAMAGED OR CON (4) Insert clutch alignment tool in clutch disc.
TAMINATED, R E P L A C E T H E DISC. D I S P O S E OF A L L (5) Insert alignment tool in pilot bearing and posi
D U S T AND DIRT S U S P E C T E D OF CONTAINING A S tion disc on flywheel. Be sure disc hub is positioned
B E S T O S F I B E R S OR D U S T IN S E A L E D BAGS OR correctly. Side of hub marked Flywheel Side should
CONTAINERS. T H I S W I L L H E L P MINIMIZE E X P O S U R E face flywheel (Fig. 6).
TO Y O U R S E L F AND T O O T H E R S . FOLLOW A L L REC (6) Position clutch cover over disc and on flywheel.
OMMENDED S A F E T Y PRACTICES P R E S C R I B E D B Y
T H E OCCUPATIONAL S A F E T Y AND H E A L T H ADMINIS
TRATION (OSHA) AND T H E ENVIRONMENTAL S A F E T Y
AGENCY (EPA), FOR T H E HANDLING AND DISPOSAL
OF P R O D U C T S CONTAINING A S B E S T O S .
C L U T C H COVER AND DISC R E M O V A L

(1) Remove transmission and transfer case. Refer
to Group 21, Manual Transmission section for proce
dure.
(2) If original clutch cover will be reinstalled,
mark position of cover on flywheel for assembly ref
erence. Use paint or a scriber for this purpose.
(3) If clutch cover is to be replaced, cover bolts can
be removed in any sequence. However, if original
cover will be reinstalled, loosen cover bolts evenly
and in rotation to relieve spring tension equally.
Loosen bolts a few threads at a time to avoid warp
ing cover. J8906-5
(4) Remove cover bolts and remove cover and disc
(Fig. 6). Fig. 6 Positioning Clutch Disc (Typical)
e - 12 CLUTCH SERVICE J
(7) Install clutch cover bolts finger tight. (6) Lightly scuff sand flywheel surface with
(8) Tighten cover bolts evenly and in rotation a 120/180 grit emery cloth. Then clean surface with
few threads at a time. Cover bolts must be tight wax and grease remover.
ened evenly and to specified torque to avoid dis (7) Install clutch disc and cover as outlined in this
torting cover. Tightening torques are 31 N*m (23 section.
ft. lbs.) on 2.5L engines and 54 N»m (40 ft. lbs.) on (8) Install transmission and transfer case. Refer to
4.0L engines. Group 21 for procedure.
(9) Apply light coat of Mopar high temperature
bearing grease to pilot bearing hub and splines of CLUTCH MASTER CYLINDER REMOVAL
(1) Raise vehicle.
transmission input shaft. Do not overlubricate
(2) Disconnect cylinder fluid line at quick discon
shaft splines. This will result in grease contami
nect fitting (Fig. 8). Push round disc inward to un-
nation of disc.
snap and separate fittings.
(10) Install transmission and transfer case, if (3) Lower vehicle.
equipped. Refer to procedures in Group 21.
P I L O T BEARING R E P L A C E M E N T
(1) Remove transfer case and transmission. Refer
to Group 21 for procedure.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use internal (blind hole)
puller such those as supplied in Snap On Tool Set
CG40CB to remove bearing.
(4) Lubricate new bearing with Mopar high tem
perature bearing grease.
(5) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool or
spare input shaft (Fig. 7).
Fig. 8 Location Of Fluid Line Quick Disconnect

Fitting
(4) On XJ models, instrument panel lower trim
cover can be removed for push rod access if neces
sary.
(5) Remove cotter pin and washer securing push
rod to pivot arm and slide rod off arm (Figs. 9 and
10).
(6) Remove cylinder attaching nuts and remove
cylinder. Note that cylinder mounting fasteners are
reversed (Fig. 11). Stud nut at top of cylinder flange
is accessible from passenger compartment. Bottom
bolt and nut are accessible from engine compart
ment.
CLUTCH M A S T E R CYLINDER INSTALLATION

(1) Position clutch master cylinder on dash panel
and install nut on upper mounting stud.
(2) Install cylinder bottom attaching bolt and nut.
(3) Tighten both cylinder attaching nuts to 26 Nnn
(4) Connect cylinder fluid line at quick disconnect
fitting (Fig. 8). Be sure fittings snap together se
curely.
(5) Install cylinder push rod on brake pedal or
Fig. 7 Pilot Bearing Installation pivot arm and install retaining washer and cotter
pin.
J CLUTCH SERVICE 6 - 13
CLUTCH COTTER PEDAL CYLINDER CLUTCH MASTER

MASTER PIN SUPPORT BRACKET AND
CYLINDER BRACKET LOWER BOLT CYLINDER
MOUNTING STUD
RETURN
SPRING
FLAT
WASHER
WAVE
WASHER
GASKET LOWER NUT
CYLINDER
BUSHING BRACE
J9106-2 J9106-8
Fig. 9 Clutch Push Rod Attachment—XJ Fig. 11 Clutch Master Cylinder Attachment
sembly is permanently attached to the piston. The
CLUTCH RETURN PEDAL
MASTER hydraulic lines are also permanently attached.
SPRING SUPPORT
CYLINDER BRACKET The only time the concentric bearing assembly
should be replaced is w h e n it is either leaking or
obviously damaged. The bearing should never
be replaced just because the clutch disc or cover
are being serviced. Replace the bearing only
when it has actually failed.
CONCENTRIC BEARING REMOVAL

(1) Remove transmission and transfer case. Refer
to Group 21 for procedure.
(2) Disconnect clutch master cylinder fluid line at
CYLINDER quick disconnect fitting (Fig. 8). Push fitting disc to
BRACE ward barrel shaped receptacle to release two sections
of fitting.
(3) Remove insulator plate bolts and slide plate
and rubber insulator off bleed line (Figs. 12 and 13).
(4) Remove concentric bearing retaining nut (Fig.
PEDAL 14). Pry nut up and off mounting pin on transmission
COTTER RETAINING
PIN case.
RING J9106-1
(5) Remove concentric bearing from input shaft.
Fig. 10 Clutch Push Rod Attachment—YJ (6) If bearing will be reused, secure bearing and
(6) Fill cylinder reservoir with Mopar brake fluid, piston with tape or rubber bands. Or reconnect nylon
or equivalent meeting SAE/DOT standards J1703 straps if they are still usable (Fig. 15).
and DOT 3.
CONCENTRIC BEARING INSTALLATION
(7) Install reservoir cap and bleed clutch hydraulic
(1) New concentric bearings are equipped with ny
system. Refer to procedure in this section.
lon retaining straps (Fig. 15). These straps hold the
bearing piston in place during shipment. It is not
HYDRAULIC CONCENTRIC BEARING necessary to cut the straps. Simply unhook the
REPLACEMENT T-shaped ends from the bearing before installation.
The hydraulic concentric bearing is serviced as an (2) Inspect bearing mounting pin (Fig. 16). Replace
assembly only. The release bearing portion of the as- transmission front bearing cover if pin is damaged.
8 - 14 CLUTCH SERVICE J
CONCENTRIC NYLON
Fig. 12 insulator, Plate And Bleed Screw—6-Cyl. Fig. 15 Concentric Bearing Components
INSULATOR CLUTCH
Fig. 16 Concentric Bearing Mounting Pin Location

Fig. 13 Insulator, Plate And Bleed Screw—4-Cyl. (5) Position bearing boss on mounting pin and seat
bearing against transmission case (Fig. 17).
(6) Secure bearing to mounting pin with new re
taining nut (Fig. 17).
(7) Unhook nylon straps that secure bearing pis
ton.
(8) Install insulator and plate (Figs. 12 and 13).
(9) Install transmission and transfer case.
(10) Connect clutch master cylinder fluid line.
(11) Fill and bleed clutch hydraulic system.
CLUTCH HOUSING REPLACEMENT

The clutch housing can be replaced when the trans
mission is out of the vehicle and the hydraulic con
centric bearing has been removed.
The bolts attaching the housing to the transmis
sion are located inside the housing (Fig. 18). Recom
Fig. 14 Retaining Nut Removal/Installation mended tightening torque for the clutch housing-to-
#
(3) Install bearing on transmission input shaft transmission bolts is 38 N m (28 ft. lbs.).
(Fig. 17). Be s u r e t h e transmission and housing- mating
(4) Guide bearing fluid and bleed lines through surfaces are clean before, installing an original,
openings in clutch housing. or r e p l a c e m e n t clutch housing. Dirt/foreign ma
terial trapped b e t w e e n the housing and trans-
CLUTCH SERVICE 6-15
J only enough material to reduce scoring (approximate
ly 0.001 - 0.003 in.). Heavy stock removal is not rec
ommended. Replace the flywheel if scoring is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation. It can also weaken the
flywheel and interfere with proper clutch release.
Check flywheel runout if misalignment is sus
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the fly
wheel face with a dial indicator. Mount the dial in
dicator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N ' Seal, or Loctite
Fig. 17 Concentric Bearing Installation 242 on the replacement bolt threads.
Recommended flywheel bolt torques are:
mission will cause misalignment. If
• 142 N*m (105 ft. lbs.) for 6-cylinder flywheels
misalignment is severe enough, the result will be
• 68 N-m (50 ft. lbs.) plus an additional turn of 60°
clutch drag, incomplete release and hard shift
for 4-cylinder flywheels
ing.
Inspect the teeth on the starter ring gear. If the
CLUTCH TRANSMISSION teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom
mended and preferred method of repair.
In cases where a new flywheel is not readily avail
able, a replacement ring gear can be installed. How
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
(a) Mark position of the old gear for alignment
reference on the flywheel. Use a scriber for this
purpose.
(b) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han
dling a heated ring gear.
(c) Remove the old gear by cutting most of the
J9106-3
way through it (at one point) with an abrasive cut
Fig. 18 Clutch Housing Attachment off wheel. Then complete removal with a cold chisel
or punch.
FLYWHEEL SERVICE (d) The ring gear is a shrink fit on the flywheel.
Inspect the flywheel whenever the clutch disc, This means the gear must be expanded by heating
cover and housing are removed for service. Check in order to install it. The method of heating and
condition of the flywheel face, hub, ring gear teeth, expanding the gear is extremely important. Ev
and flywheel bolts. ery surface of the gear must be heated at the same
Minor scratches, burrs, or glazing on the flywheel time to produce uniform expansion. An oven or
face can be reduced with 180 grit emery cloth. How similar enclosed heating device must be used. Tem
ever, the flywheel should be replaced if the disc con perature required for uniform expansion is approx
tact surface is severely scored, heat checked, cracked, imately 375° F.
or obviously worn.
Cleanup of minor flywheel scoring should be per
formed with surface grinding equipment. Remove
6 - 1 8 CLUTCH SERVICE
J
Component Foot P o u n d s N-m Inch P o u n d s Nm
Clutch Cover Bolts:
4-Cylinder 23 31
6-Cylinder 40 54
Concentric Bearing Fluid Fitting 132 15
Clutch Cylinder Mounting Bolts/Nuts 19 26
Clutch Cylinder Hydraulic Line Fitting:
4-Cylinder 132 15
6-Cylinder 190 21
Clutch Housing-to-Engine Bolts:
M12xl.75 55 75
3/8-16 27 37
7/16-14 43 58
Clutch Housing Cover (4-Cylinder):
Upper Bolt 16 22
Lower Bolt 55 75
Clutch Housing-to-Transmission Bolt:
AX 15 28 38
AX 5 28 38
Starter Motor Dowel Bolt 33 45
U-Joint Clamp Bolts 170 19
Rear Support-to-Crossmember Bolt 33 45
Crossmember-to-Frame Rail Bolt 30 41
J9006-18
COOLING SYSTEM
CONTENTS
page
DIAGNOSIS .. 4 SERVICE PROCEDURES
ENGINE ACCESSORY DRIVE BELTS . 29 SPECIFICATIONS . . .
ENGINE BLOCK HEATER ....... . 33
GENERAL INFORMATION of cooling fins. XJ models equipped with a 4.0L 6 cyl

Throughout this group, references are made to par inder engine and heavy duty cooling and/or air con
ticular vehicle models by alphabetical designation ditioning also have an auxiliary electric cooling fan.
(XJ or YJ) or by the particular vehicle nameplate. A
chart showing a breakdown of alphabetical designa COOLING SYSTEM COMPONENTS
tions is included in the Introduction section at the The cooling system consists of:
beginning of this manual. • A radiator
• Cooling fan (mechanical and/or electrical)
COOLING SYSTEM • Thermal viscous fan drive
The cooling system regulates engine operating tem • Fan shroud
perature. It allows the engine to reach normal oper • Radiator pressure cap
ating temperature as quickly as possible, maintains • Thermostat
normal operating temperature and prevents over • Coolant reserve/overflow system
heating. • Transmission oil cooler (if equipped with an auto
The cooling system also provides a means of heat matic transmission)
ing the passenger compartment and cooling the auto • Coolant
matic transmission fluid (if equipped). The cooling • Water pump
system is pressurized and uses a centrifugal water • Hoses and hose clamps
pump to circulate coolant throughout the system.
An optional factory installed heavy duty cooling SYSTEM COOLANT ROUTING
package is available on most models. The package For cooling system flow routings, refer to Figs. 1, 2,
consists of a radiator that has an increased number 3 or 4.
7 - 2 COOLING SYSTEM
WATER CONTROL
VALVE
Fig. 1 Coolant Flow—XJ Models with 2.5L Engine—Typical

J COOLING SYSTEM 7 - 3
Fig. 3 Coolant Flow—XJ Models with 4.0L Fig. 4 Coolant Flow—YJ Models with 4.0L
Engine—Typical Engine—Typical
7 - 4 COOLING SYSTEM J
DIAGNOSIS
PRELIMINARY CHECKS installed. If not, maximum cooling system compo
nents should be installed for model involved per
ENGINE COOLING SYSTEM OVERHEATING manufacturer's specifications.
Establish what driving conditions caused the com 4. RECENT SERVICE OR ACCIDENT RE
plaint. Abnormal loads on the cooling system such as PAIR:
the following may be the cause. Determine if any recent service has been performed
1. PROLONGED IDLE, V E R Y HIGH AMBI on vehicle that may effect cooling system. This may
ENT TEMPERATURE, SLIGHT T A I L WIND A T
be:
IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH
• Engine adjustments (incorrect timing)
SPEED, OR STEEP GRADES:
• Slipping engine accessory drive belt(s)
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at • Brakes (possibly dragging)
end of normal range. • Changed parts (incorrect water pump rotating in
• Increasing engine speed for more air flow is recom wrong direction)
mended. • Reconditioned radiator or cooling system refilling
2. T R A I L E R TOWING: (possibly under-filled or air trapped in system).
Consult Trailer Towing section of owners manual. If investigation reveals none of the above as a
Do not exceed limits. cause for engine overheating complaint, refer to fol
3. A I R CONDITIONING; ADD-ON OR AFTER lowing Symptom and Action chart.
MARKET:
A maximum cooling package should have been or
dered with vehicle if add-on or after market A/C is
SYMPTOM AND ACTION-SEE PRELIMINARY CHECKS FIRST
Symptom Action
Blinking Engine Temperature W a r n i n g N o r m a l w i t h t e m p o r a r y o p e r a t i o n w i t h h e a v y load, t o w i n g a t r a i l e r , h i g h

L i g h t O r H i g h G a u g e Indication- o u t d o o r t e m p e r a t u r e s , a n d / o r o n a s t e e p grade.
W i t h o u t Coolant L o s s
Coolant Loss I m p r o p e r r e f i l l i n g procedures can r e s u l t i n trapped a i r in t h e s y s t e m . S u b s e

q u e n t o p e r a t i o n o f t h e p r e s s u r e cap a n d coolant r e s e r v e system w i l l
deaerate the cooling s y s t e m . A l o w coolant level w i l l t h e n result in the
C o o l a n t R e s e r v e Bottle. A d d coolant. I f condition persists see S y s t e m
Diagnosis.
Hot Vehicle (Not Engine): Check heat s h i e l d i n g , e x h a u s t s y s t e m , e n g i n e e m i s s i o n controls, i g n i t i o n

Heat Damage, timing, engine misfiring.
Hot Carpet, Seat,
H o t Catalytic C o n v e r t e r ,
Smoke, Burnt Odor
Hot Engine: A m o d e r a t e a m o u n t o f s o u n d f r o m h e a t i n g metal can be expected w i t h a n y

Crackling N o i s e vehicle. H o w e v e r , a crackling s o u n d f r o m t h e t h e r m o s t a t h o u s i n g , a hot
Hot Smell s m e l l a n d / o r s e v e r e local hot spots o n a n e n g i n e can indicate; blocked
S e v e r e Local H o t S p o t s coolant passages, bad casting, core s a n d d e p o s i t s a n d s u b s e q u e n t blockage,
cracked cylinder block o r head, o r b l o w n cylinder head gasket.
Coolant R e s e r v e Bottle: Level changes a r e to be expected as coolant v o l u m e fluctuates w i t h e n g i n e

Level Changes t e m p e r a t u r e . D u r i n g o p e r a t i o n at h i g h e r t e m p e r a t u r e s a n d / o r u n d e r heavy
loads, t h e coolant level i n t h e r e s e r v e bottle may increase a b o v e the F U L L
level indicated o n the bottle. I f the level i n t h e bottle is b e t w e e n the A D D a n d
F U L L m a r k s w h e n the e n g i n e is at n o r m a l o p e r a t i n g t e m p e r a t u r e , the level
s h o u l d r e t u r n to w i t h i n that range w h e n t h e e n g i n e r e t u r n s to n o r m a l
o p e r a t i n g conditions.
Coolant N o t R e t u r n i n g T o Radiator Coolant w i l l n o t r e t u r n to t h e radiator i f t h e radiator cap v e n t valve d o e s n o t

f u n c t i o n , i f a n a i r leak destroys v a c u u m , o r i f t h e o v e r f l o w passage i s
blocked or restricted. Inspect all p o r t i o n s o f t h e o v e r f l o w passage, p r e s s u r e
cap, f i l l e r neck n i p p l e , h o s e , a n d passages w i t h i n t h e bottle f o r vacuum leak
only. Coolant r e t u r n f a i l u r e w i l l be e v i d e n t by a l o w level in the radiator.
R e s e r v e bottle level s h o u l d increase d u r i n g heat-up.
4.0L E n g i n e O n l y ( M J and XJ): The Fan w i l l r u n w h e n the air conditioning compressor is engaged regard
A u x i l i a r y Cooling Fan less o f coolant t e m p e r a t u r e . I f f a n r u n s w h e n compressor is not engaged,
a n d coolant t e m p e r a t u r e in the radiator o u t l e t tank i s b e l o w 8 8 ° C ( 1 9 0 ° F ) ,
C o n s u l t G r o u p 8, Electrical S e c t i o n .
J9207-1
7 - 6 COOLING S Y S T E M
J
SYSTEM DIAGNOSIS
NOISE 0) Fan contacting shroud. 0) Reposition shroud and inspect engine

mounts.
(2) Loose water pump impeller. (2) Replace pump.
(3) Glazed fan belt. (3) Replace belt.
(4) Loose fan belt. (4) Adjust fan belt tension.
(5) Rough surface on drive pulley. (5) Replace pulley.
(6) W a t e r pump bearing w o r n . (6) Remove belt to isolate. Replace pump.
(7) Belt alignment. (7) Check pulley alignment. Repair as

necessary.
R e f e r t o O v e r h e a t i n g Causes i n a d d i t i o n t< > the following items.

COOLANT L O S S —
BOILOVER (1) Overfilled cooling system. (1) Reduce coolant level t o proper
specification.
(2) Quick shutdown after hard (hot) r u n . (2) Allow engine to run at fast idle prior t o
shutdown.
(3) A i r in system, resulting in occasional (3) Purge system.

"burping" of coolant.
(4) Insufficient antifreeze, allowing coolant (4) Add antifreeze t o raise boiling point.
boiling point t o be too low.
(5) A n t i f r e e z e deteriorated because o f (5) Replace coolant.

age of contamination.
(6) Leaks due to loose hose clamps, loose (6) Pressure test system t o locate source of
nuts, bolts, drain plugs, faulty hoses, leak(s), then repair as necessary.
or defective radiator.
(7) Faulty head gasket. (7) Replace head gasket.
(8) Cracked head, manifold, o r block. (8) Replace as necessary.
(9) Faulty radiator cap. (9) Replace cap.
C O O L A N T ENTRY INTO (D Low cylinder head bolt torque. (1) Replace gasket, retorque head.
CRANKCASE OR
CYLINDER(S) (2) Faulty head gasket. (2) Replace head gasket.
(3) Crack in head, manifold o r block. (3) Replace as necessary.
COOLANT RESERVE 0) Coolant level low. 0) Replenish coolant t o F U L L mark.

SYSTEM I N O P E R A T I V E
(2) Leak in system. (2) Pressure test to isolate leak and repair
as necessary.
(3) O v e r f l o w tube clogged o r leaking. (3) Repair as necessary.
(4) Recovery bottle vent restricted. (4) Remove restriction.
LOW TEMPERATURE 0) Thermostat stuck open. 0) Replace thermostat.

GAUGE INDICATION —
UNDERCOOLING (2) Faulty gauge o r sending unit. (2) Repair o r replace faulty component.
J9107-44
COOLING S Y S T E M 7 - 7
J
SYSTEM DIAGNOSIS (CONT.)
HIGH TEMPERATURE 0) Coolant level low. 0) Replenish coolant.
G A U G E INDICATION —
OVERHEATING (2) Fan belt loose. (2) Adjust fan belt tension.
(3) Radiator hose(s) collapsed. (3) Replace hose(s).
(4) Radiator airflow blocked. (4) Remove restriction (bug screen, fog
lamps, etc.).
(5) Faulty coolant expansion bottle cap. (5) Replace coolant expansion bottle cap.
(6) A i r trapped in cooling system. m Purge air.
(7) Heavy-traffic driving. (7) Operate at fast idle in neutral

intermittently to cool engine.
(8) Incorrect cooling system component(s) (8) Install proper component(s).

installed.
(9) Faulty thermostat. W) Replace thermostat.
(10) W a t e r pump shaft broken or impeller (10) Replace water pump.

loose.
(ID Radiator tubes clogged. (ID Flush radiator.
(12) Cooling system clogged. (12) Flush system.
(13) Casting flash in cooling passages. (13) Repair or replace as necessary. Flash
may be visible by removing cooling
system components or removing core
plugs.
(14) Brakes dragging. (14) Repair brakes.
(15) Excessive engine friction. (15) Repair engine.
(16) Antifreeze concentration over 6 8 % . (16) Lower antifreeze concentration

percentage.
(17) Faulty gauge o r sending unit. (17) Repair o r replace faulty component.
(18) Loss of coolant flow caused by (18) Repair o r replace leaking component,
leakage o r foaming. replace coolant.
(19) Faulty cooling fan operation. (19) Check cooling fan operation.
N O COOLANT F L O W (D Restricted return inlet in water pump. (1) Remove restriction.

T H R O U G H HEATER CORE
(2) Heater hose collapsed or restricted. (2) Remove restriction or replace hose.
(3) Restricted heater core. (3) Remove restriction or replace core.
(4) Restricted outlet in thermostat housing. (4) Remove flash or restriction.
(5) Intake manifold bypass hole in cylinder (5) Remove restriction.

head restricted.
(6) Intake manifold coolant passage (6) Remove restriction o r replace intake
restricted. manifold.
(7) Heater valve controls not functioning. (7) Repair controls (see Heating and A i r
Conditioning Group 24).
(8) Heater valve stuck in closed position. (8) Repair or replace as necessary.
J9107-4S
SERWiCE PROCEDURES
INDEX
page page
Automatic Transmission Oil Coolers 28 Radiator Pressure Cap 19
Coolant 14 Refilling Cooling System 15
Coolant Reserve/Overflow System 18 Testing Cooling System for Leaks 17
Cooling System Cleaning/Reverse Flushing . . . . . 16 Thermostat 12
Cooling System Fans 25 Water Pump Tests . 8
Cooling System Hoses 24 Water Pumps—General Information 8
Draining Cooling System 15
Radiator . 20 Water Pumps—Removal/Installation 9
WATER PUMPS—GENERAL INFORMATION Engines from previous model years, depending

A centrifugal water pump circulates coolant upon application, may have been equipped with a
through the water jackets, passages, intake manifold, forward (clockwise) rotating water pump. Installation
radiator core, cooling system hoses and heater core. of the wrong water pump will cause engine over
The pump is driven from the engine crankshaft by a heating.
drive belt on all engines. A quick test to determine if the pump is working is
The water pump impeller is pressed onto the rear to check if the heater warms properly. A defective
of a shaft that rotates in bearings pressed into the water pump will not be able to circulate heated cool
housing. The housing has a small hole to allow seep ant through the long heater hose to the heater core.
age to escape. The water pump seals are lubricated
by the antifreeze in the coolant mixture. No addi WATER PUMP TESTS
tional lubrication is necessary.
LOOSE IMPELLER
CAUTION: All engines are equipped with a reverse DO NOT WASTE reusable coolant. If solution is
(counter-clockwise) rotating water pump and vis clean, drain coolant into a clean container for reuse.
cous fan drive assembly. R E V E R S E i s stamped or
WARNING: DO N O T R E M O V E T H E C Y L I N D E R
imprinted on the cover of the viscous fan drive and
B L O C K DRAIN P L U G S O R L O O S E N T H E R A D I A T O R
inner side of the fan. T h e letter R i s stamped into
DRAINCOCK W I T H T H E S Y S T E M H O T AND U N D E R
the back of the water pump impeller (Fig. 1).
P R E S S U R E . S E R I O U S B U R N S FROM T H E COOL
FRONT VIEW BACK V I E W
A N T CAN OCCUR.
R O T A T I O N DIRECTION R O T A T I O N DIRECTION (1) Drain the cooling system.

AS VIEWED AS VIEWED
(2) Loosen the fan belt(s).
(3) Disconnect the lower radiator hose from the
water pump.
(4) Bend a stiff clothes hanger or welding rod as
shown in (Fig. 2).
(5) Position the rod in the water pump inlet and
attempt to hold the impeller while turning the fan
blades. If equipped with a viscous fan drive, turn the
water pump shaft with a breaker bar and socket at
tached to a mounting flange nut. If the impeller is
loose and can be held with the rod while the fan
blades are turning, the pump is defective. If the im
peller turns, the pump is OK.
Connect the hose and install the coolant, or proceed
with repairs.
J9307-10 INSPECTING FOR INLET RESTRICTIONS

Inadequate heater performance may be caused by a
Fig. 1 Reverse Rotating Water Pump—Typical metal casting restriction in the water pump heater
hose inlet.
COOLING SYSTEM 7 -9
J The water pump impeller is pressed on the rear of
the pump shaft and bearing assembly. The water
pump is serviced only as a complete assembly.
WARNING: DO NOT REMOVE THE BLOCK DRAIN

PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution

is clean, drain coolant into a clean container for re
use.
(1) Disconnect negative battery cable at battery.
(2) Drain the cooling system. Refer to Draining
Cooling System in this group.
(3) XJ models with 4.0L engine equipped with
A/C or heavy duty cooling system:
Loosen (but do not remove at this time) the four
water pump pulley-to-water pump hub mounting
bolts (Fig. 3).
J9307-11
Fig. 2 Impeller Test—Typical

DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING; DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR LOOSEN T H E RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE SERIOUS BURNS FROM THE COOL
ANT CAN OCCUR,
(1) Drain sufficient coolant from the radiator to de

crease the level below the water pump heater hose
inlet. PUMP PULLEY J9307-49
(2) Remove the heater hose.
(3) Inspect the inlet for metal casting flash or Fig. 3 Water Pump Pulley Bolts
other restrictions.
XJ models with 4.0L engine without A/C or
Remove the pump from engine before remov
heavy duty cooling system; or any 2.5L engines;
ing restriction to prevent contamination of the
or any YJ models:
coolant with debris. Refer to Water Pump Re
Loosen (but do not remove at this time) the four
moval.
fan hub-to-water pump pulley mounting nuts (Fig.
4).
WATER PUMPS-REMOVAL/INSTALLATION
The engine accessory drive belt must be removed
REMOVAL-ALL MODELS prior to removing the fan (if installed at pump) or
The water pump on all models can be removed fan pulley.
without discharging the air conditioning system (if (4) Remove engine drive belt as follows:
equipped). (a) Loosen two rear power steering pump mount
ing bolts A (Fig. 5).
CAUTION: All engines have a reverse (counter (b) Loosen upper pump pivot bolt B and lower
clockwise) rotating water pump, T h e letter R i s lock nut C (Figs. 6 or 7).
stamped into the back of the water pump impeller (c) Loosen pump adjusting bolt D (Fig. 5) until
(Fig. 1) to identify. Engines from previous model belt can be removed.
years, depending upon application, may be (d) Remove belt.
equipped with a forward (clockwise) rotating water (5) Check condition of all pulleys.
pump. Installation of the wrong water pump will (6) The power steering pump must be removed
cause engine over heating. from its cast mounting bracket to gain access to bolt
7-11 COOLING SYSTEM
J
THERMAL (4) FAN BLADE-TO- (4) FAN HUB-TO-PUMP
VISCOUS VISCOUS DRIVE PULLEY STUDS
FAN DRIVE BOLTS I
(4) FAN HUB-TO-PUMP PULLEY N U T S BLADE J9307-7 J9307-3
Fig. 4 Fan Mounting Nuts Fig. 6 P.S. Pump Front Mounting

Bolt/Locknut— Typical
Fig. 7 Bracket Mounting Bolts—Typical

(11) Remove idler pulley mounting bolt and re
T
move idler pulley. This must be done to gain clear
-2
ance for the water pump mounted heater hose fitting
when water pump is being removed. Note position of
Fig. 5 P.S. Pump Rear Mounting Bolts—Typical
pulley spacers after removal.
E. Bracket mounting bolt E is located behind the
power steering pump (Fig. 7). WARNING: C O N S T A N T T E N S I O N H O S E C L A M P S
(7) Remove two bolts A (Fig. 5). A R E U S E D ON M O S T COOLING S Y S T E M H O S E S .
(8) Remove locknut C and belt adjustment bolt D W H E N REMOVING O R I N S T A L L I N G T H I S T Y P E O F
(Figs. 6 or 7). CLAMP, O N L Y U S E T O O L S D E S I G N E D F O R S E R
(9) Remove bolt B (Fig. 6). Position power steering VICING T H I S CLAMP.
pump to the side. Hold pump in position with wire.
Do not disconnect hydraulic lines from pump. (12) Remove lower radiator hose from water pump.
(10) Remove bolts E, F and G (Fig. 7) and remove Remove heater hose from water pump fitting. Special
pump mounting bracket. Clamp Tool number 6094 (Fig. 8) may be used to re
move the constant tension clamps.
COOLING SYSTEM 7-11
J
H O S E CLAMP HOSE (16) If pump is to be replaced, the heater hose fit
ting must be removed. Note position of fitting before
removal.
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. If the origi
nal pump is used, remove any deposits or other for
eign material. Inspect the cylinder block and water
pump mating surfaces for erosion or damage from
cavitation.
J9207-36 (3) Install the gasket and water pump (the gasket
is installed dry). Tighten mounting bolts to 30 N*m
Fig. 8 Hose Clamp Tool
(22 ft. lbs.) torque. Rotate the shaft by hand to be
(13) Remove four nuts or bolts (refer to the previ sure it turns freely.
ous step #3). (4) Connect the radiator and heater hoses to the
(14) Remove the fan assembly and pulley (if fan is water pump.
installed at pump), or remove the pulley from the ve (5) Position water pump pulley to water pump hub.
hicle. (6) If equipped with a water pump mounted fan,
(15) Remove the four pump mounting bolts (Fig. 9) install fan and four nuts to water pump hub. If not
and remove pump from vehicle. Discard old gasket. equipped with a water pump mounted fan, install
Note that one of the four bolts is longer than the four pump hub bolts. Tighten bolts (or nuts) to 27
other bolts.
(7) Position power steering pump bracket to en
HEATER HOSE gine. Install bolts E, F and G (Fig. 7). Tighten bolts
F and G to 38 N*m (28 ft. lbs.) torque. Tighten bolt E
to 27 Nnn (20 ft. lbs.) torque.
(8) Position power steering pump to mounting
bracket. Install pivot bolt B (Fig. 6) finger tight. In
stall locknut C and adjustment bolt D (Figs. 6 or 7)
finger tight.
(9) Install two adjustment bolts A (Fig. 6) finger
tight.
(10) Install idler pulley.
CAUTION; When installing the serpentine engine
accessory drive belt, the belt M U S T be routed cor
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
Figs. 10, 1 1 , 12 or 13 f o r appropriate belt routing.
You may also refer to the Belt Routing Label in the ve
hicle engine compartment.
(11) Position drive belt to pulleys.

(12) Tighten belt adjustment bolt D (Fig. 5) to the
proper tension. Refer to the Specifications section at
the end of this group for belt tension.
(13) Tighten bolts A (Fig. 5) to 27 N»m (20 ft. lbs.)
torque.
(14) Tighten pivot bolt B (Fig. 6) to 27 N»m (20 ft.
HOLE J9307-12 lbs.) torque.
(15) Tighten locknut C (Fig. 6) to 27 N*m (20 ft.
Fig. 9 Water Pump Remove/Install— Typical lbs.) torque.
(16) After the power steering pump has been tight
ened, recheck belt tension.
BELT TENSION
TEST POINT
J9307-50
Fig. 12 XJ Models with 4.0L Engine-Without A/C

•
BELT T E N S I O N
T E S T POINT J9307-20
Fig. 10 YJ Models with 4.0L Engine and XJ Models

with 2.5L Engine-With A/C
T BELT TENSION
TEST POINT
GENERATOR J9307-51
GEN
Fig. 13 XJ Models With 4.0L Engine-With A/C
THERMOSTAT
DESCRIPTION AND OPERATION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator. On all engines the
thermostat is closed below 195°F (90°C). Above this
• temperature, coolant is allowed to flow to the radia
BELT TENSION
T E S T POINT J9307-21 tor. This provides quick engine warmup and overall
temperature control.
Fig. 11 YJ Models With 2.5L or 4.0L Engine and XJ An arrow plus the word UP is stamped on the
Models with 2.5L Engine-Without A/C front flange next to the air bleed. The words TO
RAD are stamped on one arm of the thermostat.
They indicate the proper installed position.
(17) Fill cooling system with coolant and check for The same thermostat is used for winter and sum
leaks. Refer to Refilling Cooling System in this mer seasons. An engine should not be operated with
group. out a thermostat, except for servicing or testing.
(18) Connect battery cable to battery. Operating without a thermostat causes other prob
(19) Start and warm the engine. Check for leaks. lems. These are: longer engine warmup time, unreli
able warmup performance, increased exhaust
emissions and crankcase condensation. This conden
sation can result in sludge formation.
COOLING SYSTEM 7 - 13
J
CAUTION; Do not operate an engine without a ther
LONG GASKET THERMOSTAT
mostat, except for servicing or testing.
ON-BOARD DIAGNOSTICS
XJ and YJ models are equipped with On-Board Di
agnostics. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC). The code number
for low coolant temperature is 17. For other DTC
numbers, refer to On-Board Diagnostics in the Gen
eral Diagnosis section of group 14, Fuel Systems.
REMOVAL
WARNING: DO N O T L O O S E N T H E R A D I A T O R
DRAINCOCK W I T H T H E S Y S T E M H O T AND P R E S
S U R I Z E D . S E R I O U S B U R N S FROM T H E COOLANT
CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution SHORT

is clean, drain the coolant into a clean container for BOLT J9307-13
reuse.
Fig. 15 Thermostat Removal/Installation
(1) Drain the coolant from the radiator until the
level is below the thermostat housing. (5) Clean the gasket mating surfaces.
WARNING: C O N S T A N T T E N S I O N H O S E C L A M P S INSTALLATION
A R E U S E D ON M O S T COOLING S Y S T E M H O S E S . (1) Install the replacement thermostat so that the
W H E N REMOVING O R I N S T A L L I N G T H I S T Y P E O F pellet, which is encircled by a coil spring, faces the
CLAMP, ONLY U S E T O O L S D E S I G N E D F O R S E R engine. All thermostats are marked on the outer
VICING T H I S CLAMP. flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl
(2) Remove radiator upper hose and heater hose at inder head (Fig. 16).
thermostat housing. Special Clamp Tool number
6094 (Fig. 14) may be used to remove the constant
tension clamps.
H O S E CLAMP HOSE
J9207-36

(3) Disconnect wiring connector at engine coolant GROOVE i J9307-25
temperature sensor.
(4) Remove thermostat housing mounting bolts, Fig. 16 Thermostat Recess
thermostat housing, gasket and thermostat (Fig. 15).
Discard old gasket.
(b) Position thermostat in groove with arrow and down to -67.7°C (-90°F). A higher percentage will
air bleed hole on outer flange pointing up. freeze at a warmer temperature. Also, a higher per
(2) Install replacement gasket and thermostat centage of antifreeze can cause the engine to over
housing. heat because specific heat of antifreeze is lower than
that of water.
CAUTION; Tightening the thermostat housing un
evenly or with the thermostat out of its recess, may CAUTION: Richer antifreeze mixtures cannot be
result in a cracked housing, measured with normal field equipment and can
cause problems associated with 100 percent ethyl
(3) Tighten the housing bolts to 20 N*m (15 ft. lbs.) ene-glycol.
torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant tempera COOLANT SELECTION-ADDITIVES
ture sensor. Coolant should be maintained at the specified level
(6) Be sure that the radiator draincock is tightly with a mixture of ethylene glycol-based antifreeze
closed. Fill the cooling system to the correct level and low mineral content water. Only use an anti
with the required coolant mixture. Refer to Refilling freeze containing ALUGARD 340-2 ™.
Cooling System in this group.
CAUTION: Do not use coolant additives that are
(7) Start and warm the engine. Check for leaks.
claimed to improve engine cooling.
COOLANT
GENERAL INFORMATION COOLANT SERVICE
The cooling system is designed around the coolant. It is recommended that the cooling system be
Coolant flows through the engine water jackets ab drained and flushed at 84,000 kilometers (52,500
sorbing heat produced during engine operation. The miles), or 3 years, whichever occurs first. Then every
coolant carries heat to the radiator and heater core. two years, or 48,000 kilometers (30,000 miles),
Here it is transferred to ambient air passing through whichever occurs first.
the radiator and heater core fins. The coolant also re
moves heat from the automatic transmission fluid in COOLANT LEVEL CHECK-ROUTINE
vehicles equipped with an automatic transmission. Do not remove radiator cap for routine coolant
level inspections. The coolant level can be
COOLANT PERFORMANCE checked at coolant reserve/overflow tank.
The required ethylene-glycol (antifreeze) and water The coolant reserve/overflow system provides a
mixture depends upon climate and vehicle operating quick visual method for determining coolant level
conditions. The coolant performance of various mix without removing radiator pressure cap. With engine
tures follows: idling and at normal operating temperature, observe
Pure Water-Water can absorb more heat than a coolant level in reserve/overflow tank. The coolant
mixture of water and ethylene-glycol. This is for pur level should be between ADD and FULL marks.
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion. ADDING ADDITIONAL COOLANT-ROUTINE
100% Ethylene-Glycol-The corrosion inhibiting Do not remove radiator cap to add coolant to
additives in ethylene-glycol need the presence of wa system. When adding coolant to maintain correct
ter to dissolve. Without water, additives form depos level, do so at coolant reserve/overflow tank. Use a
its in system. These act as insulation causing 50/50 mixture of ethylene-glycol antifreeze contain
temperature to rise to as high as 149°C (300°F). This ing Alugard 340-2 ™ and low mineral content water.
temperature is hot enough to melt plastic and soften Remove radiator cap only for testing or when refill
solder. The increased temperature can result in en ing system after service. Removing cap unnecessarily
gine detonation. In addition, 100 percent ethylene- can cause loss of coolant and allow air to enter sys
glycol freezes at ^22°C (-8°F). tem, which produces corrosion.
50/50 E t h y l e n e - G l y c o l and Water-Is the recom
mended mixture, it provides protection against freez COOLANT LEVEL CHECK-SERVICE
ing to -37°C (-35°F). The antifreeze concentration The cooling system is closed and designed to main
must a l w a y s be a minimum of 44 percent, year- tain coolant level to top of radiator.
round in all climates. I f percentage is lower, engine
parts may be eroded b y cavitation. Maximum protec WARNING: DO NOT O P E N R A D I A T O R DRAINCOCK
tion against freezing is provided with a 88 percent W I T H ENGINE RUNNING O R W H I L E ENGINE I S HOT
antifreeze concentration, which prevents freezing AND COOLING S Y S T E M I S U N D E R P R E S S U R E .
J COOLING S Y S T E M 7 -1 5
When vehicle servicing requires a coolant level (a) On 2.5L engines (all models) by removing
check in radiator, drain several ounces of coolant drain plug at left rear side of block.
from radiator drain cock. Do this while observing (b) On 4.0L engines (YJ Models only) by remov
coolant reserve/overflow system tank. The coolant ing the drain plug or coolant temperature sensor
level in reserve/overflow tank should drop slightly. If on the left side of the block (Fig. 17).
not, inspect for a leak between radiator and coolant
reserve/overflow system connection. Remove radiator
cap. The coolant level should be to top of radiator. If
not and if coolant level in reserve/overflow tank is at
ADD mark, check for:
• An air leak in coolant reserve/overflow tank or its
hose
• An air leak in radiator filler neck
• Leak in pressure cap seal to radiator filler neck
LOW COOLANT LEVEL-AERATION

If the coolant level in radiator drops below top of
radiator core tubes, air will enter cooling system.
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 / tW i i ; ; i i# i i
COOLANT BLOCK
core resulting in low heat output. EMPERATURE DRAIN
SENSOR PLUG J9107-65
DEAERA TION
As the engine operates, any air trapped in cooling Fig. 17 Draining Coolant—4.0L Engine
system gathers under the radiator cap. The next time XJ MODELS WITH 4.0L ENGINE.
the engine is operated, thermal expansion of coolant
will push any trapped air past radiator cap into the WARNING: DO N O T R E M O V E T H E C Y L I N D E R
coolant reserve/overflow tank. Here it escapes to the B L O C K DRAIN P L U G S OR L O O S E N T H E R A D I A T O R
atmosphere into the tank. When the engine cools DRAINCOCK W I T H S Y S T E M H O T AND U N D E R
down the coolant, it will be drawn from the reserve/ P R E S S U R E . S E R I O U S B U R N S FROM COOLANT
overflow tank into the radiator to replace any re CAN OCCUR,
moved air.
DRAINING COOLING SYSTEM is clean, drain the coolant into a clean container for
reuse.
ALL MODELS-EXCEPT XJ WITH 4.0L ENGINE (1) Remove radiator pressure cap.
(2) For access to radiator draincock, remove radia
WARNING: DO N O T R E M O V E T H E C Y L I N D E R tor grille (Fig. 18).
B L O C K DRAIN P L U G S OR L O O S E N T H E R A D I A T O R (3) Attach one end of a 24 inch long X 1/4 inch ID
DRAINCOCK W I T H S Y S T E M H O T AND U N D E R hose to the radiator draincock. Put the other end into
P R E S S U R E . S E R I O U S B U R N S FROM COOLANT a clean container. Open draincock and drain coolant
CAN OCCUR. from radiator.
(4) Drain coolant from engine by removing the
DO NOT WASTE reusable coolant. If the solution drain plug and coolant temperature sensor on left
is clean, drain the coolant into a clean container for side of block (Fig. 17).
reuse.
DO NOT remove the radiator cap when draining REFILLING COOLING SYSTEM
the coolant from the reserve/overflow tank. Open the
radiator draincock and when the tank is empty, re YJ MODELS
move the radiator cap. The coolant does not have to (1) Remove draining hose. Tighten the radiator
be removed from the tank unless the system is being draincock and the cylinder block drain plug(s).
refilled with a fresh mixture. (2) Fill system using a 50/50 mixture of water and
(1) Drain the coolant from the radiator by loosen antifreeze. This is described in the Coolant section of
ing the draincock. this group. Fill the radiator to the top and install the
(2) Drain coolant from engine as follows: radiator cap. Add sufficient coolant to the reserve/
7-16 COOLING SYSTEM 4
CLEANING
Drain cooling system and refill with water. Run
engine with radiator cap installed until upper radia
tor hose is hot. Stop engine and drain water from
system. If water is dirty, fill system with water, run
engine and drain system. Repeat until water drains
clean.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forc
ing of water through the cooling system. This is done
using air pressure in the opposite direction of normal
coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator fit
tings. Attach a section of radiator hose to the radia
J8907-19
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
Fig, 18 Draincock Access—XJ Models with 4.0L the flushing gun.
Engine
CAUTION: T h e cooling system normally operates at
overflow tank to raise the level to the FULL mark. 97-to-124 kPa (14-to-18 psi) pressure. Exceeding
(3) Operate the engine with the radiator cap and this pressure may damage the radiator or hoses.
reserve/overflow tank cap in place. After the engine
has reached the normal operating temperature, shut Allow the radiator to fill with water. When radia
the engine off and allow it to cool. tor is filled, apply air in short blasts allowing radia
(4) Add coolant to the reserve/overflow tank as tor to refill between blasts. Continue this reverse
necessary. Only add coolant when the engine is flushing until clean water flows out through rear of
cold. Coolant level in a warm engine will be radiator cooling tube passages. For more information,
higher due to thermal expansion. refer to operating instructions supplied with flushing
equipment. Have radiator cleaned more extensively
MJ MODELS by a radiator repair shop.
(1) Tighten the radiator draincock and the cylinder
REVERSE FLUSHING ENGINE
block drain plug(s). If removed, install coolant tem
Drain the cooling system. Remove the thermostat
perature sensor (4.0L engine).
housing and thermostat. Install the thermostat hous
(2) Fill system using a 50/50 mixture of water and
ing. Disconnect the radiator upper hose from the ra
antifreeze as described in the Coolant section of this diator and attach the flushing gun to the hose.
group. Fill radiator to top and install radiator cap. Disconnect the radiator lower hose from the water
Add sufficient coolant to reserve/overflow tank to pump. Attach a lead away hose to the water pump
raise level to FULL mark. inlet fitting.
(3) With heater control unit in the HEAT position,
operate engine with radiator cap in place. CAUTION: On X J models, be sure that the heater
(4) After engine has reached normal operating control valve i s closed (heat off). T h i s i s done to
temperature, shut engine off and allow it to cool. prevent coolant flow with scale and other deposits
(5) Add coolant to reserve/overflow tank as neces from entering the heater core.
sary. Only add coolant when the engine is cold.
Coolant level in a warm engine will be higher Connect the water supply hose and air supply hose
due to thermal expansion. to the flushing gun. Allow the engine to fill with wa
ter. When the engine is filled, apply air in short
COOLING SYSTEM CLEANING/REVERSE FLUSHING blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
CAUTION: T h e cooling system normally operates at away hose. For more information, refer to operating
9740-124 kPa (14-to-18 psi) pressure. Exceeding instructions supplied with flushing equipment.
this pressure may damage the radiator or hoses. Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo
stat housing and install thermostat. Install the ther-
COOLING SYSTEM 7-17
J
mostat housing with a replacement gasket. Refer to PRESSURE TESTER METHOD
Thermostat Replacement. Connect the radiator hoses. The engine should be at the normal operating tem
Refill the cooling system with the correct antifreeze/ perature. Recheck the system cold if the cause of
water mixture. coolant loss is not located during warm engine exam
ination.
CHEMICAL CLEANING
In some instances, use a radiator cleaner (Mopar WARNING: H O T , P R E S S U R I Z E D COOLANT CAN
Radiator Kleen or equivalent) before flushing. This C A U S E I N J U R Y B Y SCALDING.
will soften scale and other deposits and aid the flush
ing operation. Carefully remove the radiator pressure cap from
the filler neck and check the coolant level. Push
CAUTION; Be sure instructions on the container are down on the cap to disengage it from the stop tabs.
followed. Wipe the inner part of the filler neck and examine
the lower inside sealing seat for nicks, cracks, paint,
dirt and solder residue. Inspect the reserve/overflow
TESTING COOLING SYSTEM FOR LEAKS tank tube for internal obstructions. Insert a wire
through the tube to be sure it is not obstructed.
ULTRAVIOLET LIGHT METHOD Inspect the cams on the outside part of the filler
All Jeep™ models have a leak detection additive neck. If the cams are bent, seating of pressure cap
added to the cooling system before they leave the fac valve and tester seal will be affected. Bent cams can
tory. The additive is highly visible under ultraviolet be reformed if done carefully. Attach pressure tester
light (black light). If the factory original coolant has 7700 or an equivalent to the radiator filler neck (Fig.
been drained, pour one ounce of additive into the 20).
cooling system. The additive is available through the
COOLING SYSTEM
part's department. Place the heater control unit in
PRESSURE TESTER
HEAT position. Start and operate the engine until
the radiator upper hose is warm to the touch. Aim
the black light (tool 7138 or an equivalent), at the
components to be checked. If leaks are present, the
black light will cause the additive to glow a bright
green color.
The black light can be used along with a pressure
tester to determine if any external leaks exist (Fig.
19).
BLACK LIGHT
(TOOL 7138)
LI9107-27
Fig. 20 Pressurizing System—Typical

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:
• Holds Steady: If the pointer remains steady for two
minutes, there are no serious coolant leaks in the
system. However, there could be an internal leak
that does not appear with normal system test pres
sure. Inspect for interior leakage or do the Internal
Leakage Test. Do this if it is certain that coolant is
being lost and no leaks: can be detected.
• Drops Slowly: Shows a small leak or seepage is oc
curring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect the radiator,
Fig. 19 Leak Detection Using Black Light—Typical hoses, gasket edges and heater. Seal any small leak
7-18 COOLING SYSTEM 4
holes with a Sealer Lubricant or equivalent. Repair DRAINCOCK W I T H T H E S Y S T E M H O T AND U N D E R

leak holes and reinspect the system with pressure P R E S S U R E . S E R I O U S B U R N S FROM COOLANT
applied. CAN OCCUR.
• Drops Quickly: Shows that a serious leakage is oc
curring. Examine the system for serious external Drain sufficient coolant to allow for thermostat re
leakage. If no leaks are visible, inspect for internal moval. Refer to Thermostat Replacement. Disconnect
leakage. Large radiator leak holes should be repaired the water pump drive belt.
by a reputable radiator repair shop. Disconnect the upper radiator hose from the ther
mostat housing. Remove the housing and thermostat.
INTERNAL LEAKAGE INSPECTION Install the thermostat housing.
Remove the oil pan drain plug and drain a small Add coolant to the radiator to bring the level to
amount of engine oil. Coolant, being heavier, will within 6.3 mm (1/4 in) of the top of the thermostat
drain first, or operate engine to churn oil, then ex housing.
amine dipstick for water globules. Inspect the trans
mission dipstick for water globules. Inspect the CAUTION: Avoid overheating. Do not operate the
transmission fluid cooler for leakage. Operate the en engine f o r an excessive period of time. Open the
gine without the pressure cap on the radiator until draincock immediately after the test to eliminate
thermostat opens. boil over of coolant.
Attach a Pressure Tester to the filler neck. If pres
sure builds up quickly, a leak exists as result of a Start the engine and accelerate rapidly three times
faulty cylinder head gasket or crack in the engine. (to approximately 3000 rpm) while observing the
Repair as necessary. coolant. If internal engine combustion gases are leak
ing into the cooling system, bubbles will appear in
WARNING: DO N O T A L L O W P R E S S U R E T O E X the coolant. If bubbles do not appear, there is no in
C E E D 124 K P A (18 P S I ) . T U R N T H E ENGINE O F F . ternal combustion gas leakage.
T O R E L E A S E T H E P R E S S U R E , ROCK T H E T E S T E R
FROM S I D E T O S I D E . W H E N REMOVING T H E COOLANT R E S E R V E / O V E R F L O W S Y S T E M
T E S T E R , DO N O T T U R N T H E T E S T E R M O R E T H A N This system works along with the radiator pressure
1/2 T U R N I F T H E S Y S T E M IS U N D E R P R E S S U R E . cap. This is done by using thermal expansion and
contraction of the coolant to keep the coolant free of
If there is no immediate pressure increase, pump trapped air. It provides:
the Pressure Tester until the indicated pressure is • A volume for coolant expansion and contraction.
within the system range. Vibration of the gauge • A convenient and safe method for checking/adjust
pointer indicates compression or combustion leakage ing coolant level at atmospheric pressure. This is
into the cooling system. done without removing the radiator pressure cap.
• Some reserve coolant to cover minor leaks and
WARNING: DO N O T DISCONNECT T H E S P A R K evaporation or boiling losses.
P L U G W I R E S W H I L E T H E ENGINE I S O P E R A T I N G . The coolant reserve system has a radiator mounted
pressurized cap, an overflow tube and a plastic cool
ant reserve/overflow tank (Fig. 21).
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. T h e catalytic HOSE RADIATOR
converter may be damaged.
Isolate the compression leak by shorting each

spark plug to the cylinder block. The gauge pointer
should stop or decrease vibration when spark plug
for leaking cylinder is shorted. This happens because
of the absence of combustion pressure.
COMBUSTION LEAKAGE TEST (WITHOUT

PRESSURE TESTER)
is clean, drain the coolant into a clean container for
reuse.
BOTTLE J9007-34
B L O C K DRAIN P L U G S O R L O O S E N T H E R A D I A T O R Fig. 21 Coolant Reserve/Overflow System—Typical
J COOLING S Y S T E M 7 - 1 9
R A D I A T O R P R E S S U R E CAP RADIATOR CAP-TO-FILLER NECK

All radiators are equipped with a pressure cap. SEAL-PRESSURE RELIEF CHECK
This cap releases pressure at some point within a With radiator cap installed on filler neck, remove
range of 83-110 kPa (12-16 psi). The pressure relief coolant reserve/ overflow tank hose from nipple on
point (in pounds) is engraved on top of the cap (Fig. filler neck. Connect a hand operated vacuum pump
22). to nipple. Operate pump until a reading of 47-to-61
The cooling system will operate at pressures kPa (14-to-18 in. Hg) appears on gauge. If the read
slightly above atmospheric pressure. This results in a ing stays steady, or drops slightly and then remains
higher coolant boiling point allowing increased radi steady, the pressure valve seal is good. Replace radi
ator cooling capacity. The cap (Fig. 22) contains a ator cap if reading does not hold.
spring-loaded pressure relief valve. This valve opens
when system pressure reaches the release range of WARNING: T H E WARNING W O R D S -DO NOT O P E N
83-110 kPa (12-16 psi). HOT- ON T H E R A D I A T O R P R E S S U R E CAP (FIG. 22)
A R E A S A F E T Y PRECAUTION. WHEN HOT, P R E S
T O P VIEW
S U R E B U I L D S U P IN COOLING S Y S T E M . T O P R E
V E N T SCALDING OR I N J U R Y , T H E R A D I A T O R CAP
S H O U L D NOT B E R E M O V E D W H I L E T H E S Y S T E M
IS H O T AND/OR U N D E R P R E S S U R E .
There is no need to remove the radiator cap except

for the following purposes:
(1) To check and adjust antifreeze freeze point.
(2) To refill system with new antifreeze.
(3) For conducting service procedures.
(4) When checking for vacuum leaks.
WARNING: I F V E H I C L E H A S B E E N R U N R E C E N T L Y ,
W A I T A T L E A S T 15 M I N U T E S B E F O R E REMOVING
R A D I A T O R CAP. W I T H A RAG, S Q U E E Z E RADIA
CROSS-SECTIONAL V I E W
T O R U P P E R H O S E T O CHECK I F S Y S T E M I S U N
D E R P R E S S U R E . P L A C E A RAG O V E R T H E CAP
AND W I T H O U T PUSHING DOWN, R O T A T E C A P
COUNTER-CLOCKWISE T O T H E F I R S T STOP. AL
LOW FLUID T O E S C A P E THROUGH OVERFLOW
HOSE INTO COOLANT R E S E R V E / O V E R F L O W
TANK. S Q U E E Z E RADIATOR U P P E R HOSE T O D E
TERMINE WHEN P R E S S U R E HAS BEEN R E
VACUUM VALVE L E A S E D . W H E N COOLANT AND S T E A M S T O P
V E N T VALVE BEING P U S H E D INTO T A N K AND S Y S T E M P R E S
( S H O W N I N SEALING POSITION) J9207-5 S U R E D R O P S , R E M O V E R A D I A T O R C A P COM
PLETELY.
Fig. 22 Radiator Pressure Cap
A vent valve in the center of the cap allows a small
PRESSURE TESTING RADIATOR CAPS
coolant flow through the cap when coolant is below
Remove cap from radiator. Be sure that sealing
boiling temperature. The valve is completely closed
surfaces are clean. Moisten rubber gasket with water
when boiling point is reached. As coolant cools, it
and install the cap on pressure tester (tool 7700 or
contracts and creates a vacuum in the cooling sys
an equivalent) (Fig. 23).
tem. This causes the vacuum valve to open and cool
Operate the tester pump and observe the gauge
ant in reserve/overflow tank to be drawn through
pointer at its highest point. The cap release pressure
connecting hose into radiator. If the vacuum valve is
should be 83-to-110 kPa (12-to-16 psi). The cap is sat
stuck shut, radiator hoses will collapse on cool down.
isfactory when the pressure holds steady. It is also
A rubber gasket seals the radiator filler neck. This good if it holds pressure within the 83-to-110 kPa
is done to maintain vacuum during coolant cool down (12-to-16 psi) range for 30 seconds or more. If the
and to prevent leakage when system is under pres pointer drops quickly, replace the cap.
sure.
L O O S E N T H E R A D I A T O R DRAINCOCK W I T H T H E
SYSTEM H O T AND P R E S S U R I Z E D . SERIOUS
B U R N S FROM T H E COOLANT CAN OCCUR.

WARNING; C O N S T A N T T E N S I O N H O S E C L A M P S
A R E U S E D ON M O S T COOLING S Y S T E M H O S E S .
W H E N REMOVING O R I N S T A L L I N G T H I S T Y P E O F
CLAMP, ONLY U S E T O O L S D E S I G N E D F O R S E R
VICING T H I S T Y P E O F CLAMP, S U C H A S T O O L
6094 (FIG. 24).
H O S E CLAMP HOSE
Fig. 23 Pressure Testing Radiator Pressure Cap

INSPECTION
Visually inspect the pressure valve gasket on the
cap. Replace cap if the gasket is swollen, torn or
worn. Inspect the area around radiator filler neck for
white deposits that indicate a leaking cap, J9207-36
RADIATOR Fig. 24 Hose damp Tool
GENERAL INFORMATION MJ MODELS WITH 2.SL ENGINE

All radiators are down flow types except XJ models
REMOVAL
with 4.0L engines. Radiators in XJ models equipped
with the 4.0L six-cylinder engine, are the cross flow
(2) Observe the previous WARNINGS. Remove ra
type. Plastic tanks are used on all radiators.
diator cap.
CAUTION: Plastic tanks, while stronger than brass, (3) Position drain pan under draincock. Open radi
are subject to damage by impact, such as ator draincock. Drain radiator.
wrenches. (4) Remove radiator upper and lower hose clamps
and hoses.
If plastic tank has been damaged, plastic tank (5) Remove alignment dowel E-clip from radiator
and/or O-rings are available for service repair. Tank lower mounting bracket (Fig. 25).
replacement should be done by qualified personal (6) Disconnect coolant reserve/overflow tank hose
with proper equipment. from radiator.
(7) Remove radiator fan shroud mounting screws
RADIATOR COOLANT FLOW CHECK (Fig. 26). Push shroud back against front of engine.
The following procedure will determine if coolant is (8) If equipped, disconnect and plug automatic
flowing through the cooling system. transmission fluid cooler lines.
If engine is cold, idle engine until normal operating (9) Remove radiator top mounting bolts (Fig. 26).
temperature is reached. Then feel the upper radiator (10) Remove the radiator grille mounting screws.
hose. If hose is hot, the thermostat is open and water Remove grille (Fig. 27).
is circulating through cooling system. \ (11) Remove the air conditioning condenser-to-ra
diator mounting screw. Use an open end wrench to
RADIATOR REMOVAL/INSTALLATION
remove bottom screws (Fig. 28).
WARNING: DO N O T R E M O V E T H E C Y L I N D E R (12) Lift radiator straight up and out of vehicle.
B L O C K DRAIN P L U G S , R A D I A T O R C A P , O R Take care not to damage radiator fins.
COOLING SYSTEM 7 - 21
RADIATOR
CONDENSER GRILLE
SCREW
6 N-m DRAINCOCK
(55 IN-LBS)
BRACKET J8907-19
J8907-17
Fig. 27 Grille Remove/Install—Cherokee Models
Fig. 25 Radiator Remove/install—XJ Models—2.5L With 2.5L Engine
Engine
CONDENSER 6 N-m RECEIVER/DRIER
TOP (55 I N . LBS.)
MOUNTING
BOLTS
J8907-20
J9007-24
Fig. 28 Condenser Mounting Screws—XJ Models

Fig. 26 Shroud Remove/Install—XJ Models With With 2.5L Engine
2.5L Engine
(6) If equipped, connect automatic transmission
INSTALLATION fluid cooler lines to radiator.
(1) Install radiator behind air conditioning con (7) Install the radiator fan shroud. Connect the
denser with bottom alignment dowel inserted into ra coolant reserve tank hose.
diator lower mounting bracket. (8) Connect radiator hoses and install hose clamps.
(2) Install E-clip to alignment dowel. (9) Connect battery negative cable.
(3) Tighten the four condenser-to-radiator mount (10) Close the draincock.
ing bolts to 6.2 N»m (55 in. lbs.) torque.
(11) Fill cooling system with correct coolant.
(4) Install radiator grille.
(12) Install radiator cap.
(5) Tighten radiator top mounting bolts to 6 N»m
(55 in. lbs.) torque.
(13) Check and adjust automatic transmission fluid straight up and out of engine compartment.
level (if equipped). (8) Remove the mechanical (non-electrical) fan
shroud mounting screws. Lift shroud up until align
XJ MODELS WITH 4.0L ENGINE ment tabs at the bottom are clear of slots in bracket
at bottom of radiator (Fig. 30). Place shroud over me
chanical fan.
B L O C K DRAIN P L U G S OR L O O S E N T H E R A D I A T O R
CAN OCCUR.

WARNING: C O N S T A N T T E N S I O N H O S E C L A M P S
CLAMP, O N L Y U S E T O O L S D E S I G N E D F O R S E R
VICING T H I S T Y P E O F C L A M P S U C H A S T O O L 6094
(FIG. 24)
REMOVAL
(2) Observe the previous WARNINGS.
(3) Remove pressure cap.
(4) For access to radiator draincock, remove radia
tor grille (Fig. 27).
(5) Attach one end of a 24 inch long X 1/4 inch ID
hose to the radiator draincock. Put the other end into
a clean container. Open draincock and drain radia Fig. 30 Auxiliary Fan and Mechanical Fan
tor. Shroud—Remove/Install— Typical
(6) If equipped, disconnect electric cooling fan elec (9) If equipped, disconnect and plug automatic
trical connector (Fig. 29). transmission fluid cooler lines. If equipped with re
mote cooler, remove line to cooler from bracket at
bottom of radiator.
(10) Disconnect radiator upper and lower hoses.
(11) Mark the position of the hood latch striker on
the radiator crossmember and remove hood latch
striker.
(12) Remove radiator upper crossmember bracket.
(13) Remove radiator upper crossmember.
(14) If equipped with air conditioning, separate ra
diator from condenser by removing condenser-to-radi
ator mounting brackets (Fig. 31).
(15) Lift radiator straight up and out of engine
compartment taking care not to damage fins.
INSTALLATION
The radiator has two alignment dowels. They are
located on the bottom tank and fit into rubber grom
mets in the radiator lower crossmember.
(1) Lower radiator into engine compartment. Posi
tion alignment dowels into grommets in radiator
lower crossmember (Fig. 32).
(2) If equipped with air conditioning, attach con
Fig. 29 Auxiliary Fan—Remove/Install denser to radiator with mounting brackets (Fig. 31).
(7) Remove electric fan mounting screws. Lift fan (3) Install radiator upper crossmember.
J COOLING SYSTEM 7 23
screws to 4 N*m (36 in. lbs.) torque.

(9) Connect electric cooling fan electrical connec
tor.
(10) Install mechanical cooling fan shroud. Insert
alignment tabs at bottom of shroud into slots in
bracket at bottom of radiator. Tighten mounting
screws to 4 N»m (36 in. lbs.) torque (Fig. 30).
(11) Close radiator draincock.
(12) Install grille.
(13) Connect battery negative cable.
(14) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(15) Install pressure cap.
(16) Check and adjust automatic transmission fluid
level (if equipped).
YJ MODELS
J-8907-26
Fig. 31 Condenser-to-Radiator Mounting
CAN OCCUR.
Brackets—XJ with 4.0L Engine
VICING T H I S T Y P E O F CLAMP S U C H A S T O O L 6094
(FIG. 24).
REMOVAL
(2) Observe the previous WARNINGS. Remove
the radiator cap.
(3) Position drain pan under draincock. Open radi
ator draincock and drain radiator.
(4) Remove radiator upper and lower hose clamps
and hoses.
(5) Disconnect coolant reserve/overflow tank hose
from radiator.
(6) Remove fan shroud screws and push shroud
Fig. 32 Radiator installation—XJ Models with 4.0L back onto fan (Fig. 33).
Engine (7) If equipped, disconnect and plug automatic
(4) Install radiator upper crossmember bracket. transmission fluid cooler lines.
(5) Install hood latch striker. (8) Remove radiator attaching screws.
(6) Connect radiator upper and lower hoses. (9) Lift radiator straight up and out of vehicle tak
(7) If equipped, connect automatic transmission ing care not to damage radiator fins.
fluid cooler lines. If equipped with remote cooler, at
tach cooler line to bracket at bottom of radiator. INSTALLATION
(8) Install electric cooling fan (if equipped). Insert (1) Install the radiator. Tighten the mounting
alignment tabs at bottom of fan shroud into slots in screws to 8 N*m (6 ft. lbs.) torque (Fig. 33).
bracket at bottom of radiator. Tighten mounting (2) Close radiator draincock.
RADIATOR (2) Install grill.
SHROUD
(2.5L ENGINE)
Fig. 33 Radiator—Remove/Install— YJ Models

(3) Install fan shroud. Tighten mounting screws to
16 N-m (11 ft. lbs.) torque.
(4) If equipped, remove plugs and connect auto
matic transmission fluid cooler lines.
(5) Connect radiator hoses and install hose clamps.
(6) Connect battery negative cable.
Fig. 34 Draincock Service—XJ Models with 4.0L
(7) Fill cooling system with correct coolant. Refer
Engine
to the Coolant section of this group.
(8) Connect reserve/overflow tank hose. XJ MODELS WITH 2.5L ENGINES AND ALL YJ
(9) Install radiator cap. MODELS
(10) Check and adjust automatic transmission fluid
level (if equipped). REMOVAL
(1) Turn the drain cock stem (counterclockwise) to
RAMATOR DRAINCOCK SERVICE unscrew the stem. When the stem is unscrewed to
All radiator draincocks are replaceable. The the end of the threads, pull the stem (Fig. 35) from
threaded fitting in the radiator outlet tank is not re the radiator tank and draincock body.
placeable. (2) Remove the draincock body from the radiator
tank. This is done by squeezing the sides together
with a pair of needle nose pliers (Fig. 36). Pull the
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
body from the inlet tank.
DRAINCOCK W I T H T H E S Y S T E M H O T A N D U N D E R
P R E S S U R E . S f M O U S B U R N S FROM COOLANT
INSTALLATION
CAN OCCUR.
(1) Check the draincock to be sure the body is in
stalled loosely on the stem (Fig. 37). If the stem is
XJ MODELS WITH 4.QL ENGINES screwed into the body, the draincock cannot be in
stalled into the tank opening.
REMOVAL (2) Push the loosely assembled draincock-assem-
Radiators used in XJ models with 4.0L engines bly-body into the tank opening until it snaps into
have a plastic draincock with an integral O-ring seal. place.
Two arms hold the draincock in place once it has (3) Tighten the draincock stem by turning clock
been completely unscrewed. wise to 2.0-to-2.7 N-m (18-to-25 in. lbs.) torque.
(1) Remove grill to gain access to draincock. Refer
to Radiator Removal/Installation—XJ With 4.0L En COOLING SYSTEM HOSES
gine in this group. Rubber hoses route coolant to and from the radia
(2) Pull draincock out of radiator tank once it has tor, intake manifold and heater core. All XJ models
been completely loosened (Fig. 34). equipped with air conditioning have a coolant control
valve. This is located in-line with the heater core in
INSTALLATION let and outlet hoses. It controls coolant flow to the
(1) Push the replacement draincock into the radia heater core when the Air Conditioning system is in
tor tank and tighten. operation.
VICING T H I S T Y P E OF CLAMP S U C H A S T O O L 6094
(FIG. 38).
H O S E CLAMP HOSE
Fig. 35 Draincock Disassembled

J9207-36

Inspect the hoses at regular intervals. Replace
hoses that are cracked, feel brittle when squeezed, or
swell excessively when the system is pressurized.
Be sure that the hoses are positioned with suffi
cient clearance from the exhaust system, fan blades,
drive belts and sway bars. This should be done in ar
eas where specific routing clamps are not provided. If
improperly positioned, the hoses will be damaged, re
sulting in coolant loss and overheating.
When performing a hose inspection, inspect the ra
diator lower hose for proper position and condition of
the internal spring.
COOLING SYSTEM FANS

All models are equipped with a mechanical temper
Fig, 36 Removing Draincock Body—Typical ature controlled fan. The viscous fan drive is a
torque-and-temperature-sensitive clutch unit. It auto
STEM matically increases or decreases fan speed to provide
proper engine cooling. XJ models equipped with a
4.0L engine also may have an auxiliary electrical
fan. This is with models that have air conditioning
and/or heavy duty cooling.
VISCOUS FAN DRIVE OPERATION

The viscous fan drive (Fig. 39) is a silicone-fluid-
filled coupling. On some engines it connects the fan
assembly to the fan/water pump pulley. The coupling
RR07B27 allows the fan to be driven in a normal manner. This
is done at low engine speeds while limiting the top
Fig. 37 Draincock Assembled for Installation speed of the fan to a predetermined maximum level
Radiator lower hoses are spring-reinforced to pre at higher engine speeds. A bimetallic spring coil is
vent collapse from water pump suction at moderate located on the front face. This spring coil reacts to
and high engine speeds. the temperature of the radiator discharge air. It en
gages the viscous fan drive for higher fan speed if
J
the air temperature from the radiator rises above a hole in the shroud. Be sure that there is adequate
certain point. Until additional engine cooling is nec clearance from the fan blades.
essary, the fan will remain at a reduced RPM regard (3) Connect a tachometer and an engine ignition
less of engine speed. timing light (timing light is to be used as a strobe
Only when sufficient heat is present, will the vis light).
cous fan drive engage. This is when the air flowing (4) Block the air flow through the radiator. Secure
through the radiator core causes a reaction from the a sheet of plastic in front of the radiator (or air con
bimetallic coil. It then increases fan speed to provide ditioner condenser). Use tape at the top to secure the
the necessary additional engine cooling. plastic and ensure that the air flow is blocked.
Once the engine has cooled, the radiator discharge (5) Be sure that the air conditioner (if equipped) is
temperature will drop. The bimetallic coil again re turned off.
acts and the fan speed is reduced to the previous dis
engaged speed. WARNING: U S E E X T R E M E CAUTION W H E N T H E
ENGINE I S O P E R A T I N G . DO N O T S T A N D IN A DI
CAUTION: Engines equipped with serpentine drive R E C T L I N E W I T H T H E F A N . DO N O T P U T Y O U R
belts have reverse rotating fans and viscous fan HANDS N E A R T H E P U L L E Y S , B E L T S O R F A N . DO
drives. They are marked with the word R E V E R S E to NOT W E A R L O O S E CLOTHING.
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat (6) Start the engine and operate at 2400 RPM with
ing. the timing light (strobe light) aimed at the fan
blades. Within ten minutes the air temperature (in
dicated on the dial thermometer) should be 88° C
(190° F). Satisfactory operation of the fan drive re
quires that it engage before or at 88° C (190° F). En
gagement is distinguishable by a definite increase in
flow noise. The timing light also will indicate an in
crease in the speed of the fan.
(7) When the air temperature reaches 88° C (190°
F), remove the plastic sheet. Satisfactory operation of
the viscous fan requires the air temperature to drop
20° F (11° C) or more. A definite decrease of audible-
fan-air-flow-noise should be noticed. Replace defec
tive fan assemblies.
VISCOUS FAN DRIVE REPLACEMENT
REMOVAL
Some engines have the mechanical fan/viscous fan
drive assembly mounted directly to the water pump
hub (Fig. 40). It may also be mounted to a hub/bear
ing attached to an aluminum bracket on the right
{18 FT. IMS.) J8907-28 front side of engine (Fig. 41).
(1) Loosen but do not remove at this time, the four
Fig. 39 Viscous Fan Drive—Typical fan hub mounting nuts (Figs. 40 or 41).
VISCOUS FAN DRIVE TEST (2) Remove accessory serpentine drive belt. Refer
The cooling system must be in good condition. This to Belt Service in the Engine Accessory Drive Belt
is checked prior to performing the following test. It section of this group.
also will ensure against excessively high coolant (3) Some models with certain engines may require
temperature. the removal of the fan shroud to remove the viscous
fan drive. The fan shroud and fan blade/viscous fan
CAUTION: B e sure that there i s adequate fan blade drive should be removed from the vehicle as one as
clearance before drilling. sembly.
(4) Remove four fan hub mounting nuts (Figs. 40
(1) Drill a 3.18-mm (1/8-in) diameter riole in the or 41) and remove fan/viscous fan drive assembly
top center of the fan shroud. from vehicle.
(2) Obtain a dial thermometer with an 8 inch stem After removing fan blade/viscous fan drive assem
(or equivalent). It should have a range of -18°-to- bly, do not place thermal viscous fan drive in hori
105°C (0°-to-220° F). Insert thermometer through the zontal position. If stored horizontally, silicone fluid in
THERMAL (4) FAN BIADE-TO- (4) FAN HUB-TO-PUMP

VISCOUS VISCOUS DRIVE PULLEY S T U D S drive belt, the belt MUST be routed correctly. If not,
FAN DRIVE BOLTS 1 the engine may overheat due to the water pump ro
tating in the wrong direction. Refer to appropriate
Engine Accessory Drive Belt Schematic in this
group for correct belt routing.
(3) Install accessory drive belts. Tension belts to

specifications. Refer to the Specifications section at
the end of this group.
FAN BLADE INSPECTION

The fan blades cannot be repaired. If the fan is
damaged, it must be replaced. Inspect the fan blades
as follows:
Lay fan blade assembly on a flat surface with lead
ing edge facing down. With tip of blade touching flat
surface, replace fan if clearance between opposite
blade and surface is greater than 2.0 mm (.090 inch).
Rocking motion of opposite blades should not exceed
(4) FAN HUB-TO-PUMP PULLEY N U T S BLADE J9307-7
2.0 mm (.090 inch). Test all blades in this manner.
Fig. 40 Water Pump Mounted Cooling Fan WARNING: IF F A N I S N O T W I T H I N SPECIFICA
TIONS, DO N O T A T T E M P T T O B E N D OR
S T R A I G H T E N FAN.
Inspect fan assembly for cracks, bends, loose rivets

or broken welds. Replace fan if any damage is found.
CAUTION: If the fan blade assembly is replaced be

cause of mechanical damage, the water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to ex
cessive vibration.
AUXILIARY ELECTRIC COOLING FAN
XJ MODELS WITH 4ML ENGINE
OPERATION
XJ models equipped with a 4.0L engine also may
have an auxiliary electrical fan. This is with models
that have air conditioning and/or heavy duty cooling.
The fan is controlled by the cooling fan relay, which
is located in the Power Distribution Center (PDC).
Fig. 41 Bracket Mounted Cooling Fan
For location of relay within the PDC (Fig. 42), refer
viscous fan drive could drain into its bearing assem to label under PDC cover.
bly and contaminate lubricant. When coolant temperature is above 88°C (190°F),
the powertrain control module (PCM) grounds the re
INSTALLATION lay. Battery voltage is then applied to the fan
(1) Assemble fan blade to viscous fan drive. through the relay. When coolant temperature is be
Tighten mounting bolts to 27 Nnn (20 ft. lbs.) torque. low 88°C (190°F), the PCM opens the ground path to
(2) Position mounting flange of fan blade/viscous the relay. This will prevent the cooling fan from be
fan drive assembly onto hub. Install four nuts and ing energized.
tighten to 24 N*m (18 ft. lbs.) torque. Tighten the Whenever the air conditioning is used, the PCM
first two nuts 180 degrees apart. Then tighten last engages the auxiliary cooling fan. It provides a
two nuts. ground path to the cooling fan relay.
POWER COOLANT ELECTRIC MOUNTING

DISTRIBUTION RECOVERY COOLING F A N BOLT
CENTER BOTTLE
J 9 ! 14-91

DIAGNOSIS
The powertrain control module (PCM) will enter a
diagnostic trouble code (DTC) in memory. This is
J8907-23
done if it detects a problem in the auxiliary cooling
fan relay or circuit. Trouble Code information can be Fig. 43 Auxiliary Fan—Remove/Install
accessed through the DRB II diagnostic tool. It also
can be accessed by cycling the ignition switch ON- • An external auxiliary oil-to-air cooler. This is
OFF-ON-OFF-ON. This cycling must be done within mounted in front of the radiator and air conditioning
five seconds. After cycling is completed, read the condenser and behind the grille.
trouble code through the instrument panel mounted An auxiliary automatic transmission oil cooler is
Malfunction Indicator Lamp (formerly referred to as standard equipment on XJ Models (Fig. 44) equipped
the Check Engine Lamp). Refer to Group 14, Fuel with:
Systems for more DTC information. • 4.0L engine
• Factory installed optional heavy duty cooling
REMOVAL • Trailer towing package B
The auxiliary fan is attached to the radiator upper
crossmember behind the radiator.
(1) Remove the fan retaining screws from radiator AIR AUXILIARY AUTOMATIC
CONDITIONING T R A N S M I S S I O N OIL
upper crossmember (Fig. 43).
CONDENSER COOLER
(2) Disconnect the electric fan connector.
(3) Lift fan straight up and out of vehicle.
INSTALLATION
(1) Align lower retaining tabs of fan shroud with
slots in bracket at bottom of radiator. Push fan down
into position.
(2) Tighten the mounting screws to 4 N®m (31 in.
lbs.) torque.
(3) Connect auxiliary cooling fan electrical connec
tor.
AUTOMATIC T R A N S M I S S I O N OIL COOLERS

There are two types of automatic transmission oil
coolers:
• An oil-to-coolant type. This is mounted in the ra
diator outlet tank.
MOUNTING
SCREW J8907-36
Fig. 44 Auxiliary Auto. Trans. Oil Cooler—XJ Models

ENGINE ACCESSORY DRIVE BELTS
INDEX
page page
Belt Diagnosis 29 Belt Tension . 29
Belt Schematics 31 Belt Tension Specifications 29
Belt Service 32 General Information 29
GENERAL INFORMATION being tested (between two pulleys) to check tension

(Figs. 2, 3, 4 or 5). Do not allow the gauge (or gauge
CAUTION: When installing a serpentine accessory adapter) to contact anything but the belt.
drive belt, the belt M U S T be routed correctly. If not,
the engine may overheat due to water pump rotat B E L T TENSION SPECIFICATIONS
ing in wrong direction. Refer to the appropriate en Proper belt tension for a new serpentine accessory
gine Belt Schematic in this Group f o r the correct drive belt is 800-900 N (180-200 lbs. force). For a
belt routing. Or, refer to the Belt Routing Label lo used serpentine accessory drive belt, the proper belt
tension is 623-712 N (140-160 lbs. force).
cated in the engine compartment.
B E L T DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 1), are considered normal.
These are not a reason to replace the belt. However,
N O R M A L CRACKS
cracks running along a rib (not across) are not nor BELT O K
mal. Any belt with cracks running along a rib must
be replaced (Fig. 1). Also replace the belt if it has ex
cessive wear, frayed cords or severe glazing.
Refer to the Serpentine Accessory Drive Belt Diag
nosis charts for further belt diagnosis.
B E L T TENSION
Correct drive belt tension is required to ensure op
timum performance of the belt driven engine acces
sories. There are different types of adjustment
gauges for checking either a serpentine or a V-type N O T N O R M A L CRACKS
belt. Refer to the instructions supplied with the REPLACE BELT
J90O7-44
gauge. Use the correct gauge when checking belt ten
sion. Place gauge in the middle of the section of belt Fig. 1 Serpentine Belt Wear Patterns
SERPENTINE DRIVE BELT DIAGNOSIS
RIB C H U N K I N G (1) Foreign objects imbedded in Remove foreign objects from

(ONE OR MORE RIBS pulley grooves. pulley grooves. Replace belt.
HAS SEPARATED
FROM BELT BODY) (2) Installation damage. Replace belt.
RIB OR BELT W E A R (1) Pulley(s) misaligned. Align pulley(s).
(2) Abrasive environment. Clean pulley(s). Replace

belt if necessary.
(3) Rusted pulley(s). Clean rust from pulley(s).
(4) Sharp or jagged pulley groove tips. Replace pulley.
(5) Rubber deteriorated. Replace belt.
LONGITUDINAL (1) Belt has mistracked from pulley Replace belt.

BELT CRACKING groove.
(CRACKS BETWEEN
T W O RIBS) (2) Pulley groove tip has worn away Replace belt.
rubber to tensile member.
BELT SLIPS (1) Belt slipping because of Adjust tension.

insufficient tension.
(2) Belt or pulley subjected to Replace belt and clean pulleys.

substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.
(3) Driven component bearing failure. Replace faulty component bearing.
(4) Belt glazed and hardened from Replace belt.

heat and excessive slippage.
"GROOVE J U M P I N G " (1) Belt tension either too Adjust belt tension.
(BELT DOES N O T high or too low.
M A I N T A I N CORRECT
POSITION O N (2) Pulley(s) not within design Replace pulley(s).
PULLEY) tolerance.
(3) Foreign object(s) in grooves. Remove foreign objects from

grooves.
(4) Pulley misalignment. Align pulley(s).
(5) Belt cord line is broken. Replace belt.
BELT BROKEN (1) Excessive tension. Replace belt and adjust tension
(NOTE: IDENTIFY to specification.
A N D CORRECT
PROBLEM BEFORE (2) Tensile members damaged during
Replace belt.
N E W BELT IS belt installation.
INSTALLED)
(3) Severe misalignment.
Align pulley(s).
(4) Bracket, pulley, or bearing Replace defective component and

failure. belt.
NOISE (1) Belt slippage. Adjust belt.

(OBJECTIONAL
SQUEAL, SQUEAK, (2) Bearing noise. Locate and repair.
OR RUMBLE IS
HEARD O R FELT (3) Belt misalignment. Align belt/pulley(s).
W H I L E DRIVE BELT
IS IN OPERATION) (4) Belt-to-pulley mismatch. Install correct belt.
E8907-143
J COOLING S Y S T E M 7 - 31
SERPENTINE DRIVE BELT DIAGNOSIS (CONT.)
NOISE (5) Driven component induced (5) Locate defective driven component
(OBJECTIONAL vibration. and repair.
SQUEAL, SQUEAK,
OR R U M B L E IS (6) System resonant frequency (6) Vary belt tension w i t h i n
HEARD O R FELT induced vibration. specifications. Replace belt.
W H I L E DRIVE BELT
IS IN OPERATION)
(Continued)
TENSION SHEETING (1) Tension sheeting contacting (1) Correct rubbing condition.
FABRIC FAILURE stationary object.
(WOVEN FABRIC O N
OUTSIDE CIRCUM (2) Excessive heat causing woven (2) Replace belt.
FERENCE OF BELT fabric to age.
HAS CRACKED O R
SEPARATED FROM (3) Tension sheeting splice has (3) Replace belt.
BODY OF BELT) fractured.
CORD EDGE FAILURE (1) Excessive tension. (1) Adjust belt tension.
(TENSILE MEMBER
EXPOSED A T EDGES (2) Belt contacting stationary object. (2) Correct as necessary.
OF BELT OR
SEPARATED FROM (3) Pulley(s) out o f tolerance. (3) Replace pulley.
BELT BODY)
(4) Insufficient adhesion between (4) Replace belt and adjust tension
tensile member and rubber matrix. to specifications.
E8907-144
BELT SCHEMATICS
Refer to figures 2, 3, 4 or 5 for proper belt routing.
Or, refer to the Belt Routing Label located in the ve
hicle engine compartment.
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
Fig. 4 XJ Models with 4.0L Engine-Without A/C
'-2
Fig. 6 P.S. Pump Rear Mounting Bolts—Typical
Fig. 5 XJ Models With 4.0L Engine- With A/C

BELT SERVICE
REPLACEMENT/ADJUSTMENT
Belt tension is adjusted at the power steering pump
(or idler pulley if not equipped with power steering).
To adjust belt tension or to replace belt:
( 1 ) Loosen two rear power steering pump mounting
bolts A (Fig. 6 ) .
( 2 ) Loosen upper pump pivot bolt B and lower lock
J9307-3
nut C (Fig. 7 ) .
( 3 ) Loosen pump adjusting bolt D (Fig. 6 ) .
Fig. 7 P.S. Pump Front Mounting
(4) If belt is to be adjusted, refer to Drive Belt Ten
Bolt/Locknut— Typical
sion specifications at the end of this group for correct
tension and proceed to step 7. ( 6 ) Install new belt. Refer to the end of this group
If belt is to be replaced, remove belt. for Drive Belt Tension specifications.
(5) Check condition of all pulleys. ( 7 ) Tighten pump adjusting bolt D (Fig. 6 ) to at
tain proper belt tension.
CAUTION: When installing the serpentine accessory ( 8 ) Tighten rear pump mounting bolts, pivot bolt
drive belt, the belt M U S T be routed correctly. If not, and lock nut to 2 7 N T H ( 2 0 ft. lbs.) torque.
the engine may overheat due to the water pump ro (9) After power steering pump has been tightened
tating in the wrong direction. Refer to (Figs. 2, 3, 4 into position, recheck belt tension. Adjust if neces
or 5) for correct belt routing. sary.
ENGINE BLOCK HEATER

DESCRIPTION AND OPERATION
An optional engine block heater is available for all
models. The heater is equipped with a power cord.
The cord is attached to an engine compartment com
ponent with tie-straps. The heater warms the engine
providing easier engine starting and faster warm-up
in low temperatures. The heater is mounted in a core
hole of the engine cylinder block (in place of a freeze
plug) with the heating element immersed in engine
coolant. Connect the power cord to a grounded 110-
120 volt AC electrical outlet with a grounded, three-
wire extension cord.
WARNING: DO N O T O P E R A T E ENGINE U N L E S S
B L O C K H E A T E R CORD H A S B E E N D I S C O N N E C T E D
FROM P O W E R S O U R C E AND S E C U R E D IN P L A C E .
Fig. 1 Heater and Cord—XJ with 2.5L Engine
BLOCK HEATER SPECIFICATIONS
• 2.5L Engine: 115 Volts 400 Watts
• 4.0L Engine: 120 Volts 600 Watts
REMOVAL
Refer to correct illustration (Figures 1, 2 or 3)
when servicing block heater.
CAN OCCUR.

(1) Drain coolant from radiator and engine cylin
der block. Fig. 2 Heater and Cord—XJ with 4.0L Engine
(2) Unplug power cord from block heater.
(3) Loosen screw in center of block heater (Fig. 1,
Fig. 2, or Fig. 3).
(4) Remove block heater from cylinder block.
INSTALLATION
(1) Thoroughly clean the engine core hole and the
block heater seat.
(2) Insert block heater assembly into core hole
with element loop pointing Up.
(3) Seat block heater flush against block face.
Tighten mounting screw to 3.6 N»m (32 in. lbs.)
torque.
(4) Fill cooling system with coolant. Pressurize sys
tem and inspect for leaks.
(5) Plug power cord into block heater. Route cord
away from moving parts, linkages and exhaust sys Fig. 3 Heater and Cord— YJ Models
tem components. Secure cord in place with tie-straps.
7 - 34 COOLING SYSTEM
J
SPECIFICATIONS
GENERAL INFORMATION
The following specifications are published from the TORQUE
tion. If anything differs between the specifica
DESCRIPTION TORQUE
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec Generator Pivot Bolt 38 N»m (28ft.lb.)
ifications, use specifications on VECI label, The Generator Rear Adj. Bolt 2 7 N T t i (20ft.lbs.)
VECI label is located in the engine compartment. Auto. Trans. Auxiliary Oil
Cooler Mtg. Screws 4.0L 2N»m(18m. lbs.)
DRIVE BELT TENSION Auxiliary Electric Cooling
Fan Mtg. Screws 4.0L 4N-m (36 in. lbs.)
• 800-900 N (180-200 lbs. force) Condenser-to-Radiator Screws
MJ/XJ Vehicles W/2.5L Eng. 6 N*m (55 in. lbs.)
(With ** new serpentine belt)
Fan Blade Assy.-to-
Viscous Fan Drive 24N*m(18ft. lbs.)
* 623-712 N (140-160 lbs. force) Viscous Fan Drive Assy.-
(With •* used serpentine belt) to-Water Pump 27 N*m (20ft.lbs.)
Fan Shroud Mtg. Bolts
MJ/XJ W/2.5L 2 N*m (20 in. lbs.)
Fan Shroud Mtg. Screws
XJ Vehicle 16N*m(12ft. lbs.)
Belt is considered new if it has been used 15 minutes or Fan Shroud Mtg. Screws
4.0L Eng. 4 N»m (31 in. lbs.)
less.
Heater Engine Cyl. Block 4 N*m (32 in. lbs.)
Radiator Mtg. Bolts
* Specifications for use with a belt tension gauge. Refer to XJ Vehicles.. 8 N*m (6 ft. lbs.)
operating instructions supplied with gauge. Radiator Mounting Bolts
MJ/XJ with 2.5L ...... 6 N»m (55 in. lbs.)
Thermostat Housing 20 N*m (15ft.lbs.)
Water Pump 2.5L and 4.0L 30 N t t i (22ft.lbs.)
J9307-53
J9307-54
COOLING SYSTEM CAPACITIES
MODEL ENGINE COOLING COOUNG RADIATOR A/C ACCESSORY MECHANICAL FAN AUXILIARY*
CAPACITY* PACKAGE DRIVE BELT (VISCOUS DRIVE) ELECTRIC FAN
2.5L 4.01 QtS. L

T
IERS STD. HD. R
OWS FINS V- SERF
. DIA. NO. B
LAD
E DIA. NO. B
LAD
E
OF P
ER B
ELT ** N
(
ICH) OF FITCH N
(
ICH) OF P
T
ICH
T
UBE
S N
IC
H B
LA
DES (INCH) B
LAD
ES (INCH)
• 10.0 9.5 • 1 15 • 16.0 5 2.5
• 10.0 9.5 • 1 20 • • 16.0 5 2.5
• 12.0 11.4 • 1 19 • 15.0 7 1.88

MJ/XJ
• 12.0 11.4 • 1 19 • • 15.0 7 1.88 11.0 6 1.75
• 12.0 11.4 • 2 19 • 15.0 7 1.88 11.0 6 1.75
• 12.0 11.4 • 2 19 • • 15.0 7 1.88 11.0 6 1.75
• 9.0 8.5 • 1 15 • 15.0 5 2.5
YJ • 10.5 9.9 2 15 • 17.25 5 2.58
• 10.5 9.9 • 2 15 • 17.25 5 2.58
4.0L ENGINE WITH HEAVY DUTY COOLING AND/OR AIR CONDITIONING

* * W A T E R PUMP AND MECHANICAL FAN ROTATE IN REVERSE (COUNTERCLOCKWISE) DIRECTION.
J9207-3
ENGINES 9 - 1
ENGINES
CONTENTS
page page
2 . 5 L ENGINE S E R V I C E P R O C E D U R E S 9 E N G I N E DIAGNOSIS 5
4 . 0 L ENGINE SERVICE P R O C E D U R E S 49 STANDARD SERVICE PROCEDURES 1
STANDARD SERVICE PROCEDURES
INDEX
page page
Engine Performance 2 Measuring with Plastigage 3
Form-ln-Place Gaskets 1 Repair Damaged or Worn Threads . . . . . . . . . . . . 4
Honing Cylinder Bores 2 Service Engine Assembly (Short Block) 4
Hydrostatic Lock 4
FORM-IN-PLACE GASKETS SURFACE PREPARATION

There are several places where form-in-place gas Parts assembled with form-in-place gaskets may be
kets are used on the engine. DO NOT use form-in- disassembled without unusual effort. In some in
place gasket material unless specified. Care must stances, it may be necessary to lightly tap the part
be taken when applying form-in-place gaskets. Bead with a mallet or other suitable tool to break the seal
size, continuity and location are of great importance. between the mating surfaces. A flat gasket scraper
Too thin a bead can result in leakage while too much may also be lightly tapped into the joint but care
can result in spill-over. A continuous bead of the must be taken not to damage the mating surfaces.
proper width is essential to obtain a leak-free joint. Scrape or wire brush all gasket surfaces to remove
Two types of form-in-place gasket materials are all loose material. Inspect stamped parts to ensure
used in the engine area (Mopar Silicone Rubber Ad gasket rails are flat. Flatten rails with a hammer on
hesive Sealant and Mopar Gasket Maker). Each have a flat plate, if required. Gasket surfaces must be free
different properties and cannot be used interchange of oil and dirt. Make sure the old gasket material is
ably. removed from blind attaching holes.
MOPAR SILICONE RUBBER ADHESIVE GASKET APPLICATION

SEALANT Assembling parts using a form-in-place gasket re
Mopar Silicone Rubber Adhesive Sealant, normally quires care.
black in color, is available in 3 ounce tubes. Moisture Mopar Silicone Rubber Adhesive Sealant should be
in the air causes the sealant material to cure. This applied in a continuous bead approximately 3 mm
material is normally used on flexible metal flanges. (0.12 inch) in diameter. All mounting holes must be
It has a shelf life of a year and will not properly cure circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
if over aged. Always inspect the package for the ex inch) drop is placed in the center of the gasket con
piration date before use. tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
MOPAR GASKET MAKER while the sealant is still wet to the touch (within 10
Mopar Gasket Maker, normally red in color, is minutes). The use of a locating dowel is recom
available in 6 cc tubes. This anaerobic type gasket mended during assembly to prevent smearing the
material cures in the absence of air when squeezed material off location.
Mopar Gasket Maker should be applied sparingly
between smooth machined metallic surfaces. It will
to one gasket surface. The sealant diameter should
not cure if left in the uncovered tube. DO NOT use
be 1.00 mm (0.04 inch) or less. Be certain the mate
on flexible metal flanges.
rial surrounds each mounting hole. Excess material
9 - 2 ENGINES J
can easily be wiped off. Components should be problems. An engine should NOT be disassem
torqued in place within 15 minutes. The use of a lo bled to determine the cause of low compression
cating dowel is recommended during assembly to pre unless some malfunction is present.
vent smearing the material off location. (5) Clean or replace spark plugs as necessary. Ad
just gap (refer to Group 8D, Ignition System for gap
ENGINE PERFORMANCE adjustment and torque).
To provide best vehicle performance and lowest ve (6) Test resistance of spark plug cables (refer to
hicle emissions, it is most important that the tune-up Group 8D, Ignition System).
be done accurately. Use the specifications listed on (7) Inspect the primary wire. Test coil output volt
the Vehicle Emission Control Information label age, primary and secondary resistance. Replace parts
found on the engine compartment hood. as necessary (refer to Group 8D, Ignition System and
(1) Test battery specific gravity. Add water, if nec make necessary adjustment).
essary. Clean and tighten battery connections. (8) Set ignition timing to specifications (refer to
(2) Test cranking amperage draw (refer to Group Specification Label on engine compartment hood).
8B, Battery/Starter Service for the proper proce (9) Perform a combustion analysis.
dures). (10) Test fuel pump for pressure and vacuum (refer
(3) Tighten the intake manifold bolts (refer to to Group 14, Fuel System for the proper specifica
Group 11, Exhaust System and Intake Manifold for tions).
the proper specifications).
(11) Inspect air filter element (refer to Group 0,
(4) Perform cylinder compression test:
Lubrication and Maintenance for the proper proce
(a) Check engine oil level and add oil, if neces
dure).
sary.
(b) Drive the vehicle until engine reaches normal (12) Inspect crankcase ventilation system (refer to
operating temperature. Group 0, Lubrication and Maintenance for the proper
(c) Select a route free from traffic and other procedure).
forms of congestion, observe all traffic laws and (13) For emission controls refer to Group 25, Emis
briskly accelerate through the gears several times. sion Controls System for service procedures.
The higher engine speed may help clean out valve (14) Inspect and adjust accessory belt drives (refer
seat deposits which can prevent accurate compres to Group 7, Cooling System for the proper adjust
sion readings. ments).
(15) Road test vehicle as a final test.
CAUTION: DO NOT overspeed t h e engine.
HONING C Y L I N D E R BORES
(d) Remove all spark plugs from engine. As Before honing, stuff plenty of clean shop towels un
spark plugs are being removed, check electrodes for der the bores and over the crankshaft to keep abra
abnormal firing indicators - fouled, hot, oily, etc. sive materials from entering the crankshaft area.
Record cylinder number of spark plug for future (1) Used carefully, the Cylinder Bore Sizing Hone
reference.
C-823 equipped with 220 grit stones, is the best tool
(e) Disconnect coil wire from distributor and se
for this job. In addition to deglazing, it will reduce
cure to good ground to prevent a spark from start
taper and out-of-round as well as removing light
ing a fire.
scuffing, scoring or scratches. Usually a few strokes
(f) Be sure throttle blades are fully open during
the compression check. will clean up a bore and maintain the required lim
(g) Insert compression gage adaptor into the its.
No.l spark plug hole. Crank engine until maxi CAUTION; DO NOT use rigid type hones to remove
mum pressure is reached on gauge. Record this cylinder wall glaze.
pressure as No.l cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders. (2) Deglazing of the cylinder walls may be done if
(i) Compression should not be less than 689 kPa the cylinder bore is straight and round. Use a cylin
(100 psi) and not vary more than 172 kPa (25 psi) der surfacing hone, Honing Tool C-3501, equipped
from cylinder to cylinder. with 280 grit stones (C-3501-3810). 20-60 strokes, de
(j) If cyUnder(s) have abnormally low compres pending on the bore condition, will be sufficient to
sion pressures, repeat steps 4a through 4h. provide a satisfactory surface. Using honing oil
(k) If the same cylinder(s) repeat an abnormally C-3501-3880 or a light honing oil available from ma
low reading, it could indicate the existence of a jor oil distributors.
problem in the cylinder.
The recommended compression pressures are CAUTION: DO NOT use engine or transmission oil,
to be used only as a guide to diagnosing engine mineral spirits or kerosene.
J ENGINES i - 3
(3) Honing SHOULD be DONE by MOVING the HONE up • ALL ENGINES—When checking No.2 main bear
AND DOWN fast ENOUGH to get a CROSSHATCH pattern. ing; shim No.l and No.3 main bearing.
The HONE MARKS SHOULD INTERSECT at 50° to 60° FOR • ALL ENGINES—When checking No.3 main bear
PROPER SEATING OF RINGS (Fig. 1). ing; shim No.2 and No.4 main bearing.
• ALL ENGINES—When checking No.4 main bear
ing; shim No.3 and No.5 main bearing.
• 2.5L ENGINE—When checking No.5 main bear
ing; shim No.4 main bearing.
Remove all shims before assembling engine.
METHOD - 2 (ALTERNATIVE)—The weight of
the crankshaft is supported by a jack under the coun
terweight adjacent to the bearing being checked.
(3) Place a piece of Plastigage across the entire
width of the bearing cap shell (Fig. 2). Position the
Fig. 1 Cylinder Bore Crosshatch Pattern Plastigage approximately 6.35 mm (1/4 inch) off cen
(4) A controlled hone motor speed between 200 and ter and away from the oil holes. In addition, suspect
300 RPM is necessary to obtain the proper CROSSHATCH areas can be checked by placing the Plastigage in
angle. The number of up and down strokes per that area. Tighten the bearing cap bolts of the bear
minute can be regulated to get the desired 50° to 60° ing being checked to 108 N*m (80 ft. lbs.) torque. DO
angle. Faster up and down strokes increase the cross- NOT rotate the crankshaft or the Plastigage may
hatch angle. be smeared, giving inaccurate results.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of ABRASIVE. Use A brush
to wash parts with a solution OF hot water and deter
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the BORE is clean. Oil the
bores after cleaning to prevent rusting.
MEASURING WITH PLASTIGAGE

CRANKSHAFT MAIN BEARING CLEARANCE
Engine crankshaft bearing clearances can be deter J93O9-90
mined by use of Plastigage, or equivalent. The fol
lowing is the recommended procedures for the use of Fig. 2 Placement of Plastigage in Bearing Shell
Plastigage: (4) Remove the bearing cap and compare the width
(1) Remove oil film from surface to be checked. of the flattened Plastigage with the scale provided on
Plastigage is soluble in oil. the package (Fig. 3). Plastigage generally comes in 2
(2) The total clearance of the main bearings can scales (one scale is in inches and the other is a met
only be determined by removing the weight OF the ric scale). Locate the band closest to the same width.
crankshaft. This can be accomplished BY either of This band shows the amount of clearance. Differ
two methods: ences in readings between the ends indicate the
METHOD - 1 (PREFERRED)—Shim the bear amount of taper present. Record all readings taken
ings adjacent to the bearing to BE checked. This will (refer to Engine Specifications).
remove the clearance between upper bearing shell (5) Plastigage is available in a variety of clearance
and the crankshaft. Place a minimum of 0.254 mm ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
(0.010 inch) shim between the bearing shell AND the is usually the most appropriate for checking engine
adjacent bearing cap. Tighten the bolts to 18 N»m (13 bearing clearances.
ft. lbs.) torque.
• ALL ENGINES-When checking No.l main bear
9 -4 ENGINES
Heli-Coil tools and inserts are readily available

J
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. If needed, the camshaft must be pro
cured separately and installed before the engine is
RN861
installed in the vehicle.
Fig. 3 Clearance Measurement A short block is identified with the letter "S" stamped
on the same machined surface where the build date
CONNECTING ROD BEARING CLEARANCE code is stamped for complete engine assemblies.
Engine connecting rod bearing clearances can be
Installation includes the transfer of components
determined by use of Plastigage, or equivalent. The
from the defective or damaged original engine. Fol
following is the recommended procedures for the use
low the appropriate procedures for cleaning, inspec
of Plastigage:
tion and torque tightening.
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil. H Y D R O S T A T I C LOCK
(2) Place a piece of Plastigage across the entire When an engine is suspected of hydrostatic lock
width of the bearing cap shell (Fig. 2). Position the (regardless of what caused the problem), follow the
Plastigage approximately 6.35 mm (1/4 inch) off cen steps below.
ter and away from the oil holes. In addition, suspect (1) Perform the Fuel Pressure Release Procedure
areas can be checked by placing the Plastigage in the (refer to Group 14, Fuel System).
suspect area. (2) Disconnect the negative cable from the battery.
(3) The crankshaft must be turned until the con (3) Inspect air cleaner, induction system and in
necting rod to be checked starts moving toward the take manifold to ensure system is dry and clear of
top of the engine. Only then should the rod cap with foreign material.
Plastigage in place be assembled. Tighten the rod (4) Place a shop towel around the spark plugs to
cap nut to 45 N»m (33 ft. lbs.) torque. DO NOT ro catch any fluid that may possibly be under pressure in
tate the crankshaft or the Plastigage may be the cylinder head. Remove the plugs from the engine.
smeared, giving inaccurate results.
(4) Remove the bearing cap and compare the width CAUTION: DO NOT use the starter motor to rotate
of the flattened Plastigage with the scale provided on the crankshaft. Severe damage could occur.
the package (Fig. 3). Plastigage generally comes in 2
(5) With all spark plugs removed, rotate the crank
scales (one scale is in inches and the other is a met
shaft using a breaker bar and socket.
ric scale). Locate the band closest to the same width.
(6) Identify the fluid in the cylinders (i.e. coolant,
This band shows the amount of clearance. Differ
fuel, oil, etc.).
ences in readings between the ends indicate the
(7) Make sure all fluid has been removed from the
amount of taper present. Record all readings taken
cylinders.
(refer to Engine Specifications).
(8) Repair engine or components as necessary to
(5) Plastigage is available in a variety of clearance
prevent this problem from occurring again.
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
(9) Squirt engine oil into the cylinders to lubricate
is usually the most appropriate for checking engine
the walls. This will prevent damage on restart.
bearing clearances.
(10) Install new spark plugs. Tighten the spark
R E P A I R DAMAGED OR W O R N T H R E A D S plugs to 37 N-m (27 ft. lbs.) torque.
Damaged or worn threads can be repaired. Essen (11) Drain engine oil. Remove and discard the oil
tially, this repair consists of: filter.
• Drilling out worn or damaged threads. (12) Install the drain plug. Tighten the plug to 41
• Tapping the hole with a special Heli-Coil Tap, or N*m (30 ft. lbs.) torque.
equivalent. (13) Install a new oil filter.
• Installing an insert into the tapped hole. (14) Fill engine crankcase with the specified
This brings the hole back to its original thread size. amount and grade of oil (refer to Group 0, Lubrica
tion and Maintenance).
CAUTION: Be sure that the tapped holes maintain (15) Connect the negative cable to the battery.
the original center line. (16) Start the engine and check for any leaks.
J ENGINES 9-5
ENGINE DIAGNOSIS
Engine diagnosis is helpful in determining the Otherwise the indicated compression pressures may
causes of malfunctions not detected and remedied by not be valid for diagnosis purposes.
routine tune-ups. (1) Clean the spark plug recesses with compressed
These malfunctions may be classified as either per air.
formance (e.g., engine idles rough and stalls) or me (2) Remove the spark plugs.
chanical (e.g., a strange noise). (3) Secure the throttle in the wide-open position.
Refer to the Service Diagnosis—Performance chart (4) Disconnect the ignition coil.
and the Service Diagnosis—Mechanical chart for pos (5) Insert a compression pressure gauge and rotate
sible causes and corrections of malfunctions. Refer to the engine with the engine starter motor for three
Group 14, Fuel System for the fuel system diagnosis. revolutions.
Additional tests and diagnostic procedures may be (6) Record the compression pressure on the 3rd
necessary for specific engine malfunctions that can revolution. Continue the test for the remaining cyl
not be isolated with the Service Diagnosis charts. In inders.
formation concerning additional tests and diagnosis Refer to Engine Specifications for the correct en
is provided within the following diagnosis: gine compression pressures.
• Cylinder Compression Pressure Test.
• Cylinder Combustion Pressure Leakage Test. ENGINE CYLINDER HEAD GASKET FAILURE
• Engine Cylinder Head Gasket Failure Diagnosis.
DIAGNOSIS
• Intake Manifold Leakage Diagnosis.
A leaking engine cylinder head gasket usually re
INTAKE MANIFOLD LEAKAGE DIAGNOSIS sults in loss of power, loss of coolant and engine mis
An intake manifold air leak is characterized by firing.
lower than normal manifold vacuum. Also, one or An engine cylinder head gasket leak can be located
more cylinders may not be functioning. between adjacent cylinders or between a cylinder and
the adjacent water jacket.
WARNING: U S E E X T R E M E CAUTION W H E N T H E • An engine cylinder head gasket leaking between
ENGINE I S O P E R A T I N G . DO N O T S T A N D IN A DI adjacent cylinders is indicated by a loss of power
R E C T L I N E W I T H T H E F A N . DO N O T P U T Y O U R and/or engine misfire.
HANDS N E A R T H E P U L L E Y S , B E L T S O R T H E F A N . • An engine cylinder head gasket leaking between a
DO NOT W E A R L O O S E CLOTHING. cylinder and an adjacent water jacket is indicated by
coolant foaming or overheating and loss of coolant.
METHOD 1 CYLINDER-TO-CYLINDER LEAKAGE TEST
(1) Start the engine. To determine if an engine cylinder head gasket is
(2) Open the acetylene valve of an oxyacetylene
leaking between adjacent cylinders; follow the proce
torch. Do not ignite.
dures outlined in Cylinder Compression Pressure
(3) Pass the torch tip over the exposed gasket area
Test. An engine cylinder head gasket leaking be
(EDGE) between the manifold and the engine cylin
tween adjacent cylinders will result in approximately
der head.
(4) If the engine speed increases, the manifold has a 50-70% reduction in compression pressure.
an air leak.
CYLINDER-TO-WATER JACKET LEAKAGE
METHOD 2 TEST
(1) Start the engine.
(2) Apply engine oil to the exposed gasket area
(EDGE) between the manifold and the engine cylin ENGINE I S O P E R A T I N G . DO N O T S T A N D IN A DI
der head. R E C T L I N E W I T H T H E F A N . DO NOT P U T Y O U R
(3) If oil is forced into the manifold and if smoke is HANDS NEAR T H E P U L L E Y S , B E L T S OR T H E FAN.
visible from the exhaust tailpipe, the manifold has DO NOT W E A R L O O S E CLOTHING.
an air leak.
Remove the radiator cap.
CYLINDER COMPRESSION P R E S S U R E T E S T Start the engine and allow it to warm up until the
The results of a cylinder compression pressure test engine thermostat opens.
can be utilized to diagnose several engine malfunc If a large combustion/compression pressure leak ex
tions. ists, bubbles will be visible in the coolant.
Ensure the battery is completely charged and the If bubbles are not visible, install a radiator pres
engine starter motor is in good operating condition. sure tester and pressurize the coolant system.
9 - S ENGINES
J
If a cylinder is leaking combustion pressure into Remove the spark plugs.
the water jacket, the tester pointer will pulsate with Remove the oil filler cap.
every combustion stroke of the cylinder. Remove the air cleaner.
Calibrate the tester according to the manufactur
CYLINDER COMBUSTION PRESSURE LEAKAGE er's instructions. The shop air source for testing
TEST should maintain 483 kPa (70 psi) minimum, 1 379
The combustion pressure leakage test provides an kPa (200 psi) maximum and 552 kPa (80 psi) recom
accurate means for determining engine condition.
mended.
Combustion pressure leakage testing will detect:
Perform the test procedures on each cylinder ac
• Exhaust and intake valve leaks (improper seat
cording to the tester manufacturer's instructions.
ing).
• Leaks between adjacent cylinders or into water While testing, listen for pressurized air escaping
jacket. through the throttle body, tailpipe and oil filler cap
• Any causes for combustion/compression pressure opening. Check for bubbles in the radiator coolant.
loss. All gauge pressure indications should be equal,
with no more than 25% leakage.
WARNING: DO NOT R E M O V E T H E R A D I A T O R CAP FOR EXAMPLE: At 552 kPa (80 psi) input pres
W I T H T H E S Y S T E M H O T AND U N D E R P R E S S U R E sure, a minimum of 414 kPa (60 psi) should be main
B E C A U S E S E R I O U S B U R N S FROM COOLANT CAN tained in the cylinder.
OCCUR. Refer to the Cylinder Combustion Pressure Leak
age Test Diagnosis chart.
Check the coolant level and fill as required. Do not
install the radiator cap.
Start and operate the engine until it attains nor
mal operating temperature, then turn the engine
OFF.
CYLINDER COMBUSTION PRESSURE LEAKAGE TEST DIAGNOSIS
AIR ESCAPES T H R O U G H Intake valve not seated properly. Inspect valve. Reface or replace, i f
CARBURETOR/THROTTLE necessary.
BODY
AIR ESCAPES Exhaust valve not seated properly. Inspect valve.Reface or replace, if
T H R O U G H TAILPIPE necessary.
AIR ESCAPES Head gasket leaks or crack in cylinder Remove cylinder head and inspect.
T H R O U G H RADIATOR block. Replace, if necessary.
M O R E T H A N 5 0 % LEAKAGE Head gasket leaks or crack in cylinder Remove cylinder head and inspect.
F R O M A D J A C E N T CYLINDERS block or head between adjacent cylinders. Replace gasket or head, if necessary.
M O R E T H A N 2 5 % LEAKAGE Stuck or broken piston ring(s); cracked Inspect for broken rinq(s) or piston.
A N D AIR ESCAPES T H R O U G H piston; worn rings and/or cylinder wall. Measure ring gap and cylinder diameter,
OIL FILLER CAP O P E N I N G O N L Y taper, and out-of-round. Replace affected
part, if necessary.
J8909-78
ENGINES 9 - 7
SERVICE DIAGNOSIS-PERFORMANCE
COND1TIOH POSSIBLE CAUSES CORRECriOH

ENGINE WILL N O T START 1 . Weak battery. 1 . Test battery specific gravity. Charge or replace as necessary.
2. Corroded or loose battery 2. Clean and tighten battery connections. Apply a coat of light
connections. mineral grease to the terminals.
3. Faulty starter. 3. Refer to Group 8 A , Battery/Starter/Charging System
Diagnostics.
4. Moisture on ignition wires and 4. W i p e wires and cap clean and dry.
distributor cap.
5. Faulty ignition cables. 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to Group 8 D , Ignition
System).
7. Incorrect spark plug gap. 7. Set gap (refer to Group 8 D , Ignition System).
8. Incorrect ignition timing. 8. Refer to Group 8 D , Ignition System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel filter.
10. Faulty fuel pump. 10. Install new fuel pump (refer to Group 14, Fuel System).
E N G I N E STALLS O R 1 . Idle speed set too low. 1 . Refer to Group 14, Fuel System.
R O U G H IDLE 2. Idle mixture too lean or too rich. 2. Refer to Group 14, Fuel System.
3. Leak in intake manifold. 3. Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 1 1 , Exhaust System & Intake
Manifold).
4. W o r n or burned distributor rotor. 4. Install new distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Test and replace, if necessary (refer to Group 8 D , Ignition
System).
7. EGR valve leaking. 7. Test and replace, if necessary (refer to Group 2 5 , Emissions
Control System).
ENGINE LOSS O F POWER 1. Incorrect ignition timing. 1 . Refer to Group 8 D , Ignition System.
3. W o r n distributor shaft. 3. Remove and repair distributor (refer to Group 8 D , Ignition
System).
4. Dirty or incorrectly gapped spark 4. Clean plugs and set gap (refer to Group 8 D , Ignition System).
plugs.
5. Dirt or water in fuel system. 5. Clean system and replace fuel filter.
6. Faulty fuel pump. 6. Install new fuel pump.
7. Incorrect valve timing. 7. Correct valve timing.
8. Blown cylinder head gasket. 8. Install new cylinder head gasket.
9. Low compression. 9. Test compression of each cylinder.
10. Burned, warped or pitted valves. 10. Install new valves.
1 1 . Plugged or restricted exhaust 11. Install new parts, as necessary.
system.
12. Faulty ignition cables. 12. Replace any cracked or shorted cables.
13. Faulty coil. 13. Test and replace, as necessary (refer to Group 8 D , Ignition
System).
ENGINE MISSES O N 1 . Dirty or gap set too wide in spark 1 . Clean spark plugs and set gap (refer to Group 8 D , Ignition
ACCELERATION plug. System).
3. Dirt in fuel system. 3. Clean fuel system.
4. Burned, warped or pitted valves. 4. Install new valves.
5. Faulty coil. 5. Test and replace, if necessary, (refer to Group 8 D , Ignition
System).
E N G I N E M I S S E S A T HIGH 1 . Dirty or gap set too wide in spark 1 . Clean spark plugs and set gap (refer to Group 8 D , Ignition
SPEED plug. System).
2. W o r n distributor shaft. 2. Remove and repair distributor (refer to Group 8 D , Ignition
System).
4. Faulty coil. 4. Test and replace, as necessary (refer to Group 8 D , Ignition
System).
6. Dirty injector in throttle body. 6. Clean injector.
7. Dirt or water in fuel system. 7. Clean system and replace fuel filter
J9209-7
9 - 8 ENGINES
J
SERVICE DIAGNOSIS-MECHANICAL
POSSIBLE CAUSES CORRECTION
NOISY VALVES 1 . High or low oil level in 1. Check f o r correct oil level (refer to Group 0, Lubrication and
crankcase. Maintenance).
2. T h i n or diluted oil. 2. Change oil (refer to Group 0, Lubrication and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets 4. Clean hydraulic tappets.
5. Bent push rods. 5. Install new push rods.
6. W o r n rocker arms. 6. Inspect oil supply to rocker arms.
7. W o r n tappets* 7. Install new hydraulic tappets.
8 . W o r n valve guides. 8 . Ream and install new valves w i t h oversize stems.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
CONNECTING R O D 1 . Insufficient oil supply. 1 . Check engine oil level (refer to Group 0, Lubrication and
NOISE Maintenance).
2. L o w oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
3. T h i n or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings f o r correct clearance. Repair as necessary.
5. Connecting rod journal out-of- 5. Replace crankshaft or grind journals.
round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
AAAIN BEARING NOISE 1 . Insufficient oil supply. 1 . Check engine oil level (refer to Group 0, Lubrication and
Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings f o r correct clearance. Repair as necessary.
5. Excessive end play. 5. Check N o . 3 main bearing f o r w e a r on flanges.
6. Crankshaft journal out-of-round, 6. Grind journals or replace crankshaft.
worn.
7. Loose flywheel or torque 7. Tighten to correct torque.
converter.
OIL PRESSURE D R O P 1 . Low oil level. 1 . Check engine oil level.

2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. W o r n parts in oil pump. 5. Replace w o r n parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Excessive bearing clearance. 7. Measure bearings f o r correct clearance.
8 . Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9. Oil pump suction tube loose, bent 9. Remove oil pan and install new tube, if necessary.
or cracked
10. Oil pump cover warped or 10. Install new oil pump.
cracked.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace the gasket.

gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the part.
metal part.
OIL PUAAPING A T RINGS; 1 . W o r n , scuffed or broken rings. 1. Hone cylinder bores and install new rings.
SPARK P L U G S F O U L I N G 2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If grooves are not proper
width, replace piston.
4. W o r n valve guides. 4. Ream guides and replace valves w i t h oversize valves and seals.
5. Leaking intake gasket. 5. Replace gasket and tighten intake manifold to proper torque.
6. Leaking valve guide seals. 6. Replace seals.
7. Dislodged valve guide seals. 7. Seat valve guide seals or replace, as needed.
J9209-14
2«5L ENGINE SERWICE PROCEDURES
INDEX
page page
Camshaft . 28 Oil Pan ..... 31
Camshaft Pin Replacement 29 Oil Pump 32
Crankshaft Main Bearings 40 Pistons and Connecting Rods 34
Cylinder Block 44 Rear Main Oil Seals 44
Engine Assembly—XJ Vehicles 12 Rocker Arms 17
Engine Assembly—YJ Vehicles 14 Specifications 46
Engine Cylinder Head 18 Timing Case Cover 26
Engine Cylinder Head Cover 16 Timing Case Cover Oil Seal Replacement . . . . . . 25
Engine Damper 12 Timing Chain and Sprockets 26
Engine Mount—Rear . . . . a 11 Valve Springs and Oil Seals 20
Engine Mounts—Front 10 Valve Timing . 24
General Information 9 Valves and Valve Springs 21
Hydraulic Tappets . 23 Vibration Damper ........................ 25
GENERAL INFORMATION
The 2.5 liter (150 CID) four-cylinder engine is an
In-line, lightweight, overhead valve engine (Fig. 1).
Engine Type . In-line 4 Cylinder

Bore and Stroke 98.4 x81.0 mm (3.88 x3.19 in.;
Displacement 2.5L (150 cu. in.)
Compression Ratio 9.1:1
Torque
(XJ Vehicles) ..... 202 N m (149 ft. lbs.) @ 3250 rpm
(YJ Vehicles) .... 196 N m (144 ft. lbs.) @ 3000 rpm ENGINE
Firing Order 1—3—4—2 FIRING ORDER
Lubrication Pressure Feed—Full Flow Filtration
Engine Oil Capacity . . . 3.8L (4 Quarts) 1-3-4-2
Cooling System Liquid Cooled—Forced Circulation
Cooling System Capacity
(XJ Vehicles) 9.5L (10 Quarts) J9209-3
(YJ Vehicles) . 8.5L (9 Quarts)
Cylinder Block Cast Iron Fig. 2 Engine Firing Order
Crankshaft Cast Nodular Iron BUILD DATE CODE
Cylinder Head . . . . . . . Cast Nodular Iron
The engine Build Date Code is located on a ma
Camshaft . . . . . . . . . . . Cast Nodular Iron
Pistons Aluminum Alloy (with Struts) chined surface on the right side of the cylinder block
Pistons Combustion between the No.3 and No.4 cylinders (Fig. 3).
Cavity Double Quench
Connecting Rods . . . . . . Cast Nodular Iron
J9309-91
Fig. 1 Engine Description

This engine is designed for unleaded fuel.
The engine cylinder head has dual quench-type
combustion chambers that create turbulence and fast
burning of the air/fuel mixture. This results in good
fuel economy.
The cylinders are numbered 1 through 4 from front >
to rear. The firing order is 1-3-4-2 (Fig. 2).

The crankshaft rotation is clockwise, when viewed
from the front of the engine. The crankshaft rotates MACHINED
within five main bearings and the camshaft rotates SURFACE J9209-5
within four bearings.
Fig. 3 Build Date Code Location
9 - 10 2.5L ENGINE J
The digits of the code identify:
(1) 1st Digit-The year (3 = 1993).
(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).
(4) 6th & 7th Digits-The day of engine build (01 -
31).
FOR EXAMPLE: Code * 301HX23 * identifies a
2.5 liter (150 CID) engine with a multi-point fuel in
jection system, 9.1:1 compression ratio and built on
January 23, 1993.
OVERSIZE AND UNDERSIZE COMPONENT

CODES
Some engines may be built with oversize or under-
size components such as:
• Oversize cylinder bores.
• Oversize camshaft bearing bores. OIL
FILTER
• Undersize crankshaft main bearing journals. BOSS J9209-9
• Undersize connecting rod journals.
These engines are identified by a letter code (Fig. Fig. 5 Oversize and Undersize Code Location
4) stamped on the oil filter boss near the distributor REMOVAL
(Fig. 5). (1) Disconnect negative cable from battery.
CODE COMPONENT UNDERSIZE
(3) Support the engine.
(4) Remove the nut from the through bolt (Figs. 7
and 8). Do not remove the through bolt.
P One or more 0.254 mm
connecting rod (0.010 in)
(5) Remove the retaining bolts/nuts from the en
bearing journals gine support cushions (Figs. 6 and 7).
(6) Remove the through bolt.
M All crankshaft 0.254 mm
main bearing (0.010 in)
(7) Remove the engine support cushions.
journals
INSTALLATION
PM All crankshaft 0.254 mm (1) If the engine support bracket was removed, po
main bearing (0.010 in) sition the bracket and install the attaching bolts
journals and
one or more
(Figs. 7 and 8). Tighten the bolts to 61 N*m (45 ft.
connecting rod lbs.) torque.
journals (2) Place the engine support cushion into position
(Figs. 7 and 8).
(3) Install the through bolt and the retaining nut
CODE COMPONENT OVERSIZE (Figs. 7 and 8).
(4) Install the engine support cushion retaining
B All cylinder 0.254 mm bolt and nut. Tighten the XJ vehicle retaining bolts/
bores (0.010 in) nuts to 41 N«m (30 ft. lbs.) torque. Tighten the YJ
C All camshaft 0.254 mm
vehicle retaining bolts/nuts to 65 N*m (48 ft. lbs.)
bearing bores (0.010 in) torque.
(5) Tighten the through bolt nut to 65 N i n (48 ft.
lbs.) torque.
(6) Remove the engine support.
J8909-54
Fig. 4 Oversize and Undersize Component Codes (8) Connect negative cable to battery.
ENGINE MOUNTS—FRONT
Resilient rubber cushions support the engine at
each side of the engine (Figs. 7 and 8).
2.5L ENGINE 9 - 11
J ENGINE MOUNT-REAR
ENGINE SUPPORT
BRACKET A resilient rubber cushion supports the transmis
sion at the rear between the transmission extension
housing and the rear support crossmember or skid
THROUGH
plate.
BOLT
REMOVAL—MJ VEHICLES
(2) Raise the vehicle and support the transmission.
(3) Remove the nuts holding the transmission sup
port cushion to the crossmember (Fig. 8).
(4) Remove the crossmember and the transmission
support cushion.
(5) If necessary, remove the bolts holding the rear
support bracket to the transmission (Fig. 8). Remove
the bracket.
REAR SUPPORT
BRACKET
FWD J9109-162
Fig. 6 Front Mounts—XJ Vehicles

ENGINE SUPPORT
BRACKET TRANSMISSION
J9109-160 SUPPORT CUSHION
ENGINE
MOUNT Fig. 8 Rear Mount—XJ Vehicles
REMOVAL— YJ VEHICLES
port cushion to the skid plate (Fig. 9).
(4) Remove the skid plate bolts and the skid plate.
(5) Remove the bolts holding the transmission sup
RETAINING THROUGH
NUT FRAME BOLT
port cushion and torque arm bracket to the transmis
sion (Fig. 9).
ENGINE SUPPORT (6) Remove the transmission support cushion and
BRACKET
torque arm bracket.
ATTACHING
BOLT INSTALLA TION—XJ VEHICLES
(1) If removed, position the rear support bracket to
the transmission and install the bolts. Tighten the
RETAINING
BOLT (2) Position the transmission support cushion and
THROUGH crossmember to the studs of the rear support bracket.
BOLT Install the crossmember-to-sill bolts and tighten to
LEFT
SIDE 41 N*m (30 ft. lbs.) torque.
(3) Remove the transmission support.
ENGINE FRONT (4) Install the rear support bracket nuts to the
CUSHION SUPPORT J9109-163
studs and tighten to 46 N*m (34 ft. lbs) torque.
Fig. 7 Front Mounts—YJ Vehicles (5) Lower the vehicle.
TORQUE ARM UPPER

BRACKET SHOCK
UPPER OUTER ABSORBER
RETAINER BRACKET
BUSHING
TRANSMISSION
SUPPORT CUSHION BUSHING
UPPER INNER
SHOCK
RETAINER
ABSORBER
SKID
PLATE T J9109-161
Fig. 9 Rear Mount—YJ Vehicles LOWER INNER

(6) Connect negative cable to battery. RETAINER
INSTALLA TION- YJ VEHICLES BUSHING
(1) Position the torque arm bracket and transmis

sion support cushion to the transmission and install
BUSHING
the bolts (Fig. 9 ) . Tighten the bolts to 5 6 N-m (41 ft.
lbs.) torque. LOWER
LOWER O U T E R
(2) Position the skid plate to the studs of the trans SHOCK ABSORBER
RETAINER
BRACKET
mission support cushion (Fig. 9), Install the skid J8909-3
#
plate bolts to the sill and tighten to 88 N m (65 ft.
lbs.) torque. Fig. 10 Engine Damper
(3) Remove the transmission support. (5) Install the bushing, upper outer retainer and
(4) Install the transmission support cushion nuts damper nut.
and tighten to 56 N-m (41 ft. lbs) torque (Fig. 9). (6) Install the bushing, lower outer retainer and
(5) Lower the vehicle. damper nut.
(6) Connect negative cable to battery. (7) Tighten the upper and lower damper nuts.
ENGINE DAMPER
ENGINE ASSEMBLY—XJ WEHIGLES
REMOVAL
(1) Disconnect negative cable from battery. REMOVAL
(2) Remove the top and bottom damper nuts (Fig. (1) Disconnect the battery cables. Remove the bat
10). tery.
(3) Remove the outer retainers and bushings (Fig. (2) Mark the hinge locations on the hood panel for
10). alignment reference during installation. Remove the
(4) Remove the top damper bracket nut and bolts engine compartment lamp. Remove the hood.
(Fig. 10).
(5) Remove the bracket, inner retainers, bushings W A R N I N G : THE COOLANT IN A R E C E N T L Y O P E R
and the damper (Fig. 10). A T E D ENGINE IS HOT A N D P R E S S U R I Z E D . U S E
C A R E T O P R E V E N T SCALDING B Y HOT COOLANT.
INSTALLATION CAREFULLY R E L E A S E T H E PRESSURE B E F O R E
(1) Install the damper on the lower bracket with REMOVING THE R A D I A T O R D R A I N COCK AND
the lower inner retainer and bushing in place. CAP.
(2) Install the upper inner retainer and bushing on
the top of the damper. (3) Remove the radiator drain cock and radiator
(3) Position the upper damper bracket over the cap to drain the coolant. Do not waste usable coolant.
damper and install the stud nut and bolts. If the solution is clean, drain the coolant into a clean
(4) Tighten the stud nut to 23 N*m (17 ft. lbs.) container for reuse.
torque. Tighten the bracket bolts to 61 N»m (45 ft. (4) Remove the lower radiator hose.
lbs.) torque.
2.5L ENGINE 9 - 13
J (5) Remove the upper radiator hose and coolant re
covery hose (Fig. 11).
(6) Remove the fan shroud (Fig. 11).
Fig. 12 Heater Hoses, Throttle Linkage & Quick-

Connect Fuel Lines
Fig. 11 Upper Radiator Hose, Coolant Recovery

Hose & Fan Shroud
(7) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(8) Remove the radiator/condenser (if equipped
with air conditioning).
(9) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and wa
ter pump in alignment when crankshaft is rotated.
(10) Disconnect the heater hoses (Fig. 12).
(11) Disconnect the throttle linkages (Fig. 12),
speed control cable (if equipped) and throttle valve
rod.
(12) Disconnect the oxygen ( 0 ) sensor wire con
2
nector.
(13) Disconnect the wires from the starter motor
solenoid.
(14) Disconnect all fuel injection harness connec
tions.
(15) Disconnect the quick-connect fuel lines at the Fig. 13 Air Cleaner and Power Steering Pump
fuel rail and return line by squeezing the two retain (c) Cap the fittings on the hoses and steering
ing tabs against the fuel tube (Fig. 12). Pull the fuel gear to prevent foreign material from entering the
tube and retainer from the quick-connect fitting (re system.
fer to Group 14, Fuel System for the proper proce (21) Disconnect the coolant hoses from the rear of
dure). the intake manifold.
(16) Remove the fuel line bracket from the intake (22) Identify, tag and disconnect all necessary wire
manifold. connectors and vacuum hoses.
(17) Remove the air cleaner assembly (Fig. 13). (23) Raise the vehicle.
(18) If equipped with air conditioning, remove the (24) Remove the oil filter.
service valves and cap the compressor ports. (25) Remove the starter motor.
(19) Remove the power brake vacuum check valve (26) Disconnect the exhaust pipe from the exhaust
from the booster, if equipped. manifold.
(20) If equipped with power steering (Fig. 13):
(27) Remove the flywheel/converter housing access
(a) Disconnect the power steering hoses from the
cover.
fittings at the steering gear.
(b) Drain the pump reservoir.
(28) If equipped with an automatic transmission, (11) Install the starter motor and connect the ca
mark the converter and drive plate location in refer ble. Tighten the bolts to 45 N*m (33 ft. lbs.) torque.
ence to each other and remove the converter-to-drive (12) Tighten the engine support cushing-to-bracket
plate bolts. through bolts to 65 N»m (48 ft. lbs.) torque.
(29) Remove the upper flywheel/converter housing (13) Install the remaining flywheel/converter hous
bolts and loosen the bottom bolts. ing bolts. Tighten the bolts to 38 N«m (28 ft. lbs.)
(30) Remove the engine support cushion-to-engine torque.
compartment bracket bolts. (14) Connect the exhaust pipe to the manifold.
(31) Remove the engine shock damper bracket (15) Install the oil filter.
from the sill. (16) Lower the vehicle.
(32) Lower the vehicle. (17) Connect the coolant hoses and tighten the
(33) Attach a lifting device to the engine. clamps.
(34) Raise the engine slightly off the front sup (18) If equipped with power steering:
ports. (a) Remove the protective caps
(35) Place a support stand under the converter or (b) Connect the hoses to the fittings at the steer
flywheel housing. ing gear. Tighten the nut to 52 N«m (38 ft. lbs.)
(36) Remove the remaining bottom converter or torque.
flywheel housing bolts. (c) Fill the pump reservoir with fluid.
(37) Lift the engine out of the engine compartment (19) Remove the pulley-to-water pump flange
and install on an engine stand. alignment capscrew and install the fan and spacer or
(38) Install the oil filter to keep foreign material Tempatrol fan assembly.
out of the engine. (20) Install the fan shroud and radiator/condenser
(if equipped with air conditioning).
INSTALLATION (21) Connect the radiator hoses.
(1) Remove the oil filter. (22) Connect the automatic transmission fluid
(2) Lift the engine off the stand and lower it into cooler pipes, if equipped.
the engine compartment. For easier installation, it (23) Connect the oxygen ( 0 ) sensor wire connec
2
may be useful to remove the engine support cushions tor.

from the engine support brackets as an aide for (24) Connect the throttle valve rod and retainer.
alignment of the engine-to-transmission. Connect the throttle cable and install the rod. Install
(3) If equipped with a manual transmission: the throttle valve rod spring.
(a) Insert the transmission shaft into the clutch (25) Connect the speed control cable, if equipped.
spline. (26) Connect the fuel supply and return lines to
(b) Align the flywheel housing with the engine.
the throttle body.
(c) Install and tighten the flywheel housing
(27) Connect all the vacuum hoses and wire con
lower bolts finger tight.
(4) If equipped with an automatic transmission: nectors.
(a) Align the transmission torque converter (28) Connect the service valves to the A/C com
housing with the engine. pressor ports, if equipped with air conditioning.
(b) Loosely install the converter housing lower (29) Fill the power steering reservoir.
bolts and install the next higher bolt and nut on (30) Connect the battery cables.
each side. (31) Install the hood.
(c) Tighten all 4 bolts finger-tight. (32) Install the air cleaner.
(5) Install the engine support cushions (if re (33) Start the engine and inspect for leaks.
moved). (34) Fill the cooling system.
(6) Lower the engine and engine support cushions (35) Stop the engine and check the fluid levels.
onto the engine compartment brackets. Add fluid, as required.
(7) Remove the engine lifting device.
(8) Raise the vehicle. ENGINE ASSEMBLY—YJ VEHICLES
(9) If equipped with an automatic transmission:
(a) Install the converter-to-drive plate bolts. En REMOVAL
sure the installation reference marks are aligned. (1) Place a protective cloth over the windshield
Tighten the bolts to 54 N*m (40 ft. lbs.) torque. frame. Raise the hood and rest it on the windshield
(b) Install the converter-housing access cover. frame (Fig. 14).
(c) Install the exhaust pipe support. (2) Disconnect the battery cable clamps and re
(10) Install the remaining converter or flywheel move the battery.
housing bolts.
Fig. 15 Fuel Line Quick-Connect Couplings
(14) Disconnect the throttle cable and remove it
from the bracket.
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if
Fig. 14 Hood on Windshield Frame equipped.
WARNING: THE COOLANT IN A R E C E N T L Y O P E R (17) Disconnect the oxygen ( 0 ) sensor wire con
2
A T E D ENGINE IS HOT AND P R E S S U R I Z E D . U S E nector.

C A R E T O P R E V E N T SCALDING B Y H O T COOLANT. (18) Disconnect the upper and lower radiator hoses
C A R E F U L L Y R E L E A S E THE P R E S S U R E B E F O R E at the radiator.
REMOVING THE R A D I A T O R DRAIN COCK AND (19) Disconnect the coolant hoses from the rear of
CAP. the intake manifold and thermostat housing.
(20) Disconnect the heater hoses.
(3) Remove the radiator drain cock and radiator (21) Remove the fan shroud screws.
cap to drain the coolant. Do not waste usable coolant. (22) Remove the radiator attaching bolts.
If the solution is clean, drain the coolant into a clean (23) Remove the radiator and fan shroud.
container for reuse. (24) Remove the fan and spacer or Tempatrol fan
(4) Disconnect the wire connectors from the gener assembly.
ator. (25) Install a 5/16 X 1/2-inch SAE capscrew
(5) Disconnect the ignition coil and distributor through fan pulley into water pump flange. This will
wire connectors. maintain the pulley and water pump in alignment
(6) Disconnect the oil pressure sender wire connec when crankshaft is rotated.
tor. (26) Remove the power brake vacuum check valve
(7) Disconnect the wires at the starter motor sole from the booster, if equipped.
noid and injection wire harness connector. (27) If equipped with power steering:
(8) Disconnect the quick-connect fuel lines at the (a) Disconnect the hoses from the fittings at the
fuel rail and return line by squeezing the two retain steering gear.
ing tabs against the fuel tube (Fig. 15). Pull the fuel (b) Drain the pump reservoir.
tube and retainer from the quick-connect fitting (re (c) Cap the fittings on the hoses and steering
fer to Group 14, Fuel System for the proper proce gear to prevent foreign objects from entering the
dure). system.
(9) Remove the fuel line bracket from the intake (28) Lift the vehicle and support it with support
manifold. stands.
(10) Disconnect the engine ground strap. (29) Remove the oil filter.
(11) Remove the air cleaner assembly. (30) Remove the starter motor.
(12) Disconnect the vacuum purge hose at the fuel (31) Remove the flywheel housing access cover.
vapor canister tee. (32) Remove the engine support cushion-to-bracket
(13) Disconnect the idle speed actuator wire con through bolts.
nector. (33) Disconnect the exhaust pipe from the mani
fold.
9 - 16 2.5L ENGINE
(34) Remove the upper flywheel housing bolts and (20) Remove the pulley-to-water pump flange
loosen the bottom bolts. alignment capscrew and install the fan and spacer or
(35) Remove the engine shock damper bracket Tempatrol fan assembly.
from the sill. (21) Tighten the serpentine drive belt according to
(36) Lower the vehicle. the specifications listed in Group 7, Cooling System.
(37) Attach a lifting device to the engine. (22) Install the fan shroud and radiator.
(38) Raise the engine off the front supports. (23) Connect the radiator hoses.
(39) Place a support stand under the flywheel (24) Connect the heater hoses.
housing. (25) Connect the throttle valve rod and retainer.
(40) Remove the remaining flywheel housing bolts. (26) Connect the throttle cable and install the rod.
(41) Lift the engine out of the engine compartment (27) Install the throttle valve rod spring.
and install on an engine stand. (28) Connect the speed control cable, if equipped.
(42) Install the oil filter to keep foreign material (29) Connect the oxygen ( 0 ) sensor wire connec
2
out of the engine. tor.

(30) Install the vacuum hose and check valve on
INSTALLATION the brake booster.
(1) Remove the oil filter. (31) Connect the coolant temperature sensor wire
(2) Lift the engine off the stand and lower it into connector.
the engine compartment. For easier installation, it (32) Connect the idle speed actuator wire connec
may be useful to remove the engine support cushions tor.
from the engine support brackets as an aide for (33) Connect the fuel inlet and return hoses at the
alignment of the engine-to-transmission. fuel rail. Verify that the quick-connect fitting assem
(3) Insert the transmission shaft into the clutch bly fits securely over the fuel lines by giving the fuel
spline. lines a firm tug.
(4) Align the flywheel housing with the engine. (34) Install the fuel line bracket to the intake
(5) Install and finger tighten the flywheel housing manifold.
lower bolts. (35) Connect all fuel injection wire connections.
(6) Install the engine support cushions (if re (36) Install the engine ground strap.
moved). (37) Connect the ignition coil wire connector.
(7) Remove the support stand from beneath the fly (38) Remove the coolant temperature sending unit
wheel housing. to permit air to escape from the block. Fill the cool
(8) Lower the engine and engine support cushions ing system with coolant. Install the coolant tempera
onto the engine compartment brackets. Ensure that ture sending unit when the system is filled.
the bolt holes are aligned. Install the bolts and (39) Install the battery and connect the battery ca
tighten to 65 N»m (48 ft. lbs.) torque. bles.
(9) Remove the engine lifting device. (40) Install the air cleaner bonnet to the throttle
body.
(11) Attach the engine shock damper bracket to
(41) Install the air cleaner.
the sill.
(42) Lower the hood and secure in place.
(12) Attach the exhaust pipe to the manifold. In
(43) Start the engine and inspect for leaks.
stall and tighten the nuts to 31 N«m (23 ft. lbs.)
(44) Stop the engine and check the fluid levels.
torque.
Add fluid, as required.
(13) Install the flywheel housing access cover.
(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.
ble. Tighten the bolts to 45 N-m (33 ft. lbs.) torque.
(16) Install the oil filter. REMOVAL
(17) Lower the vehicle. (1) Disconnect negative cable from battery.
(18) Connect the coolant hoses and tighten the (2) Disconnect the Crankcase Ventilation (CCV)
clamps. vacuum hose from engine cylinder head cover (Fig.
(19) If equipped with power steering: 1).
(a) Remove the protective caps (3) Disconnect the fresh air inlet hose from the en
(b) Connect the hoses to the fittings at the steer gine cylinder head cover (Fig. 1).
ing gear. Tighten the nut to 52 N»m (38 ft. lbs.) (4) Remove the engine cylinder head cover mount
torque. ing bolts.
(c) Fill the pump reservoir with fluid. (5) Remove the engine cylinder head cover.
J 2 J L ENGINE 9 -17
(4) Remove the bridges, pivots and corresponding

pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
Fig. 1 Engine Cylinder Head Cover

CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original grey gasket material should NOT be Fig. 2 Rocker Arm Assembly
removed. If sections of the gasket material are miss CLEANING
ing or are compressed, replace the engine cylinder Clean all the components with cleaning solvent.
head cover. However, sections with minor damage Use compressed air to blow out the oil passages in
such as small cracks, cuts or chips may be repaired the rocker arms and push rods.
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow INSPECTION
the gasket material to cure prior to engine cylinder Inspect the pivot surface area of each rocker arm.
head cover installation. Replace any that are scuffed, pitted, cracked or ex
cessively worn.
INSTALLATION Inspect the valve stem tip contact surface of each
(1) If a replacement cover is installed, transfer the rocker arm and replace any rocker arm that is deeply
CCV valve grommet the oil filler cap from the origi pitted.
nal cover to the replacement cover. Inspect each push rod end for excessive wear and
(2) Install engine cylinder head cover. Tighten the replace as required. If any push rod is excessively
mounting bolts to 9 N*m (75 in. lbs.) torque. worn because of lack of oil, replace it and inspect the
(3) Connect the CCV hoses (Fig. 1). corresponding hydraulic tappet for excessive wear.
(4) Connect negative cable to battery. Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
ROCKER ARMS the push rod and the flat surface.
This procedure can be done with the engine in or A wear pattern along the length of the push rod is
out of the vehicle. not normal. Inspect the engine cylinder head for ob
struction if this condition exists.
REMOVAL
(1) Remove the engine cylinder head cover. INSTALLATION
(2) Remove the capscrews at each bridge and pivot (1) Lubricate the ball ends of the push rods with
assembly (Fig. 2). Alternately loosen the capscrews Mopar Engine Oil Supplement, or equivalent and in
one turn at a time to avoid damaging the bridges. stall push rods in their original locations. Ensure
(3) Check for rocker arm bridges which are caus that the bottom end of each push rod is centered in
ing misalignment of the rocker arm to valve tip area. the tappet plunger cap seat.
9 - 18 2 . 5 L ENGINE
J
(2) Using Mopar Engine Oil Supplement, or equiv (12) Disconnect the ignition wires and remove the
alent, lubricate the area of the rocker arm that the spark plugs.
pivot contacts. Install rocker arms, pivots and bridge (13) Disconnect the temperature sending unit wire
above each cylinder in their originally position. connector.
(3) Loosely install the capscrews through each (14) Remove the ignition coil and bracket assem
bridge. bly.
(4) At each bridge, tighten the capscrews alter (15) Remove the engine cylinder head bolts.
nately, one turn at a time, to avoid damaging the (16) Remove the engine cylinder head and gasket
bridge. Tighten the capscrews to 28 N»m (21 ft. lbs.) (Fig. 3).
torque. (17) If this was the first time the bolts were re
(5) Install the engine cylinder head cover. moved, put a paint dab on the top of the bolt. If the
bolts have a paint dab on the top of the bolt or it
ENGINE C Y L I N D E R HEAD isn't known if they were used before, discard the
This procedure can be done with the engine in or bolts.
out of the vehicle. (18) Stuff clean lint free shop towels into the cyl
inder bores.
REMOVAL
DRAIN COCK W I T H T H E S Y S T E M H O T AND P R E S
S U R I Z E D B E C A U S E S E R I O U S B U R N S FROM T H E
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at

the engine thermostat housing. Do not waste reus
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem
blies and rocker arms (Fig. 2). Fig. 3 Engine Cylinder Head Assembly
(6) Remove the push rods (Fig. 2). Retain the CLEANING
push rods, bridges, pivots and rocker arms in Thoroughly clean the engine cylinder head and cyl
the same order as removed. inder block mating surfaces. Clean the intake and
(7) Loosen the serpentine drive belt at the power exhaust manifold and engine cylinder head mating
steering pump, if equipped or at the idler pulley (re surfaces. Remove all gasket material and carbon.
fer to Group 7, Cooling System for the proper proce Check to ensure that no coolant or foreign material
dure). has fallen into the tappet bore area.
(8) If equipped with air conditioning, perform the Remove the carbon deposits from the combustion
following: chambers and top of the pistons.
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside. INSPECTION
(b) Remove the air conditioner compressor Use a straightedge and feeler gauge to check the
bracket bolts from the engine cylinder head. flatness of the engine cylinder head and block mat
(c) Loosen the through bolt at the bottom of the ing surfaces.
bracket.
(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.
hose. If the engine cylinder head is to be replaced and
(11) Remove the intake and engine exhaust mani the original valves used, measure the valve stem di
folds from the engine cylinder head (refer to Group ameter. Only standard size valves can be used with a
11, Exhaust System and Intake Manifold for the service replacement engine cylinder head unless the
proper procedures). replacement head valve stem guide bores are reamed
J 2 . 5 L ENGINE 9 -19
to accommodate oversize valve stems. Remove all (a) Tighten all bolts in sequence (1 through 10)
carbon buildup and reface the valves. to 30 N-m (22 ft. lbs.) torque.
(1) Fabricate two engine cylinder head alignment (b) Tighten all bolts in sequence (1 through 10)
dowels from used head bolts (Fig. 4). Use the longest to 61 N-m (45 ft. lbs.) torque.
head bolt. Cut the head of the bolt off below the hex (c) Check all bolts to verify they are set to 61
head. Then cut a slot in the top of the dowel to allow N-m (45 ft. lbs.) torque.
easier removal with a screwdriver. (d) Tighten bolts (in sequence):
USED • Bolts 1 through 6 to 149 N-m (110 ft. lbs.) torque.
CYLINDER • Bolt 7 to 136 N-m (100 ft. lbs.) torque.
HEAD • Bolts 8 through 10 to 149 N-m (110 ft. lbs.) torque.
BOLT
CAUTION: During the final tightening sequence,

bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(e) Check all bolts in sequence to verify the cor
rect torque.
(f) If not already done, clean and mark each bolt
with a dab of paint after tightening. Should you
encounter bolts which were painted in an earlier
service operation, replace them.
J9009-13
Fig. 4 Fabricate Alignment Dowels

(2) Install one dowel in bolt hole No.10 and the
other dowel in bolt hole No.8 (Fig. 5).
ALIGNMENT
DOWEL
J9009-15
Fig. 6 Engine cylinder head Bolt Tightening

Sequence
Fig. 5 Alignment Dowel Locations (11) Install the ignition coil and bracket assembly.
(3) Remove the shop towels from the cylinder (12) Connect the temperature sending unit wire
bores. Coat the bores with clean engine oil. connector.
(4) Place the engine cylinder head gasket (with the (13) Install the spark plugs and tighten to 37 N-m
numbers facing up) over the dowels. (27 ft. lbs.) torque. Connect the ignition wires.
(5) Place the engine cylinder head over the dowels. (14) Install the intake and exhaust manifolds (re
fer to Group 11, Exhaust System and Intake Mani
CAUTION: Engine cylinder head bolts should be re fold for the proper procedures).
used only once. Replace the head bolts if they were (15) Install the fuel lines and the vacuum advance
used before or if they have a paint dab on the top hose.
of the bolt. (16) If equipped, attach the power steering pump
and bracket.
(6) Coat the threads of bolt No.7, only, with Loctite
(17) Install the push rods, rocker arms, pivots and
PST sealant or equivalent.
bridges in the order they were removed.
(7) Install all head bolts, except No.8 and No.10.
(18) Install the engine cylinder head cover.
(8) Remove the dowels.
(9) Install No.8 and No.10 head bolts. (19) Attach the air conditioning compressor mount
(10) Tighten the engine cylinder head bolts in se ing bracket to the engine cylinder head and block.
quence according to the following procedure (Fig. 6): Tighten the bolts to 40 N-m (30 ft. lbs.) torque.
g - 20 2 . i L ENGINE J
(20) Attach the air conditioning compressor to the (5) Remove the spark plug(s) adjacent to the cylin
bracket. Tighten the bolts to 27 N*m (20 ft. lbs.) ders) below the valve springs to be removed.
torque. (6) Install a 14 mm (1/2 inch) (thread size) air hose
adaptor in the spark plug hole. An adaptor can be
CAUTION: T h e serpentine drive belt must be routed constructed by welding an air hose connection to the
correctly. Incorrect routing can cause the water body of a spark plug with the porcelain removed.
pump to turn in the opposite direction causing the (7) Connect an air hose to the adapter and apply
engine to overheat. air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
(21) Install the serpentine drive belt and correctly against their seats. For vehicles equipped with an air
tension the belt (refer to Group 7, Cooling System for conditioner, use a flexible air adaptor when servicing
the proper procedure). the No.l cylinder.
(22) Install the air cleaner and ducting. (8) Tap the retainer or tip with a rawhide hammer
(23) Install the engine cylinder head cover. to loosen the lock from the retainer. Use Valve
(24) Connect the hoses to the thermostat housing Spring Compressor Tool MD-998772A to compress
and fill the cooling system to the specified level (re the spring and remove the locks (Fig. 7).
fer to Group 7, Cooling Systems for the proper proce (9) Remove valve spring and retainer (Fig. 7).
dure). (10) Remove valve stem oil seals (Fig. 7). Note the
(25) The automatic transmission throttle linkage valve seals are different for intake and exhaust
and cable must be adjusted after completing the en valves. The top of each seal is marked either INT
gine cylinder head installation (refer to Group 21, (Intake) or EXH (Exhaust). DO NOT mix the seals.
Transmissions for the proper procedures). valve _
(26) Install the temperature sending unit and con LOCKS
nect the wire connector.
(27) Connect the fuel pipe and vacuum advance
hose.
(29) Connect the upper radiator hose and heater
hose at the thermostat housing. VALVE
SPRING
(30) Fill the cooling system. Check for leaks.
WARNING: U S E EXTREME CAUTION WHEN THE
ENGINE I S OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(31) Operate the engine with the radiator cap off.

Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required. EXHAUST
VALVE
VALVE SPRINGS AND OIL SEALS J8909-88
This procedure can be done with the engine cylin
der head installed on the block. Fig. 7 Valve and Valve Components
INSPECTION
REMOVAL
Inspect the valve stems, especially the grooves. An
Each valve spring is held in place by a retainer
Arkansas smooth stone should be used to remove
and a set of conical valve locks. The locks can be re
nicks and high spots.
moved only by compressing the valve spring.
(2) Remove capscrews, bridge and pivot assemblies
and rocker arms for access to each valve spring to be CAUTION: Install oil seals carefully to prevent dam
removed. age from the sharp edges of the valve spring lock
(3) Remove push rods. Retain the push rods, grove.
bridges, pivots and rocker arms in the same order
and position as removed. (1) Lightly push the valve seal over the valve stem
(4) Inspect the springs and retainer for cracks and and valve guide boss. Be sure the seal is completely
possible signs of weakening. seated on the valve guide boss.
J 2 . 5 L ENGINE 9 - 21
(2) Install valve spring and retainer. (2) After refacing, a margin of at least 0.787 mm
(3) Compress the valve spring with Valve Spring (0.031 inch) must remain (Fig. 8). If the margin is
Compressor Tool MD-998772A and insert the valve less than 0.787 mm (0.031 inch), the valve must be
locks. Release the spring tension and remove the replaced.
tool. Tap the spring from side-to-side to ensure that
0.787 AAAA (1/32 INCH)
the spring is seated properly on the engine cylinder VALVE M A R G I N ,
head.
(4) Disconnect the air hose. Remove the adaptor
from the spark plug hole and install the spark plug.
(5) Repeat the procedures for each remaining valve
spring to be removed.
(6) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet. CORRECT VALVE FACING
(7) Install the rocker arms, pivots and bridge at N O AAARGIN
their original location.
(8) Tighten the bridge capscrews alternately, one
at a time, to avoid damaging the bridge. Tighten the
capscrews to 28 N*m (21 ft. lbs.) torque.
V A L V E S AND V A L V E S P R I N G S
INCORRECT VALVE FACING
This procedure is done with the engine cylinder
head removed from the block.
J8909-89
REMOVAL
(1) Remove the engine cylinder head from the cyl Fig. 8 Valve Facing Margin
inder block. VALVE SEAT REFACING
(2) Use Valve Spring Compressor Tool (1) Install a pilot of the correct size in the valve
MD-998772A and compress each valve spring. guide bore. Reface the valve seat to the specified an
(3) Remove the valve locks, retainers, springs and gle with a good dressing stone. Remove only enough
valve stem oil seals. Discard the oil seals. metal to provide a smooth finish.
(4) Use an Arkansas smooth stone or a jewelers (2) Use tapered stones to obtain the specified seat
file to remove any burrs on the top of the valve stem, width when required.
especially around the groove for the locks. (3) Control valve seat runout to a maximum of
(5) Remove the valves, and place them in a rack in 0.0635 mm (0.0025 in.)-(Fig. 9).
the same order as removed.
VALVE CLEANING
Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
Clean all grime and gasket material from the en
gine cylinder head machined gasket surface.
INSPECTION
Inspect for cracks in the combustion chambers and
valve ports.
Inspect for cracks on the exhaust seat.
Inspect for cracks in the gasket surface at each
coolant passage.
Inspect valves for burned, cracked or warped heads.
Inspect for scuffed or bent valve stems.
Replace valves displaying any damage. Fig. 9 Measurement of Valve Seat Runout
VALVE REFACING VALVE STEM OIL SEAL REPLACEMENT
(1) Use a valve refacing machine to reface the in Valve stem oil seals are installed on each valve
take and exhaust valves to the specified angle. stem to prevent rocker arm lubricating oil from en-
9 - 22 2.5L ENGINE
tering the combustion chamber through the valve (4) Remove and measure telescoping gauge with a
J
guide bores. One seal is marked INT (intake valve) micrometer.
and the other is marked EXH (exhaust valve). (5) Repeat the measurement with contacts length
Replace the oil seals whenever valve service is per wise to engine cylinder head.
formed or if the seals have deteriorated. (6) Compare the crosswise to lengthwise measure
ments to determine out-of-roundness. If the measure
VALVE GUIDES ments differ by more than 0.0635 mm (0.0025 in.),
The valve guides are an integral part of the engine ream the guide bore to accommodate an oversize
cylinder head and are not replaceable. valve stem.
When the valve stem guide clearance is excessive, (7) Compare the measured valve guide bore diam
the valve guide bores must be reamed oversize. Ser eter with specifications (7.95-7.97 mm or 0.313-0.314
vice valves with oversize stems are available in 0.076 inch). If the measurement differs from specification
mm (0.003 inch) and 0.381 mm (0.015 inch) incre by more than 0.076 mm (0.003 inch), ream the guide
ments. bore to accommodate an oversize valve stem.
Corresponding oversize valve stem seals are also
available and must be used with valves having 0.381 ALTERNATIVE METHOD:
mm (0.015 inch) oversize stems. (1) Use a dial indicator to measure the lateral
If the valve guides are reamed oversize, the movement of the valve stem (stem-to-guide clear
valve seats must be ground to ensure that the ance). This must be done with the valve installed in
valve seat is concentric to the valve guide. its guide and just off the valve seat (Fig. 11).
(2) Correct clearance is 0.025-0.0762 mm (0.001-
VALVE STEM-TO-GUIDE CLEARANCE 0.003 inch). If indicated movement exceeds the spec
MEASUREMENT ification ream the valve guide to accommodate an
Valve stem-to-guide clearance may be measured by oversize valve stem.
either of the following two methods. Valve seats must be ground after reaming the
valve guides to ensure that the valve seat is con
PREFERRED METHOD:
centric to the valve guide.
(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. 10).
GAUGE
DIAL INDICATOR
J9009-16
Fig. 11 Measurement of Lateral Movement Of Valve

VALVE Stem
STEM
GUIDE VALVE SPRING TENSION TEST
Use Valve Spring Tester C-647 and a torque
wrench to test each valve spring for the specified ten
sion value (Fig. 12).
CYLINDER
HEAD
Replace valve springs that are not within specifica
tions.
INSTALLATION
J8909-92
(1) Thoroughly clean the valve stems and the
Fig. 10 Measurement of Valve Guide Bore Diameter valve guide bores.
(2) Lightly lubricate the stem.
J 2 . I L ENGINE 9 - 23
TORQUE W R E N C H HYDRAULIC VALVE TAPPET

R E M O V A L / INSTALLATION
TOOL
VALVE SPRING
TESTER TOOL
VALVE SPRING
J9009-18
Fig. 12 Valve Spring Tester C-647

(3) Install the valve in the original valve guide
bore.
(4) Install the replacement valve stem oil seals on the J8909-96
valve stems. If the 0.381 mm (0.015 inch) oversize valve
stems are used, oversize oil seals are required. Fig. 13 Hydraulic Valve Tappet Removal/Installation
(5) Position the valve spring and retainer on the Tool C-4129-A
engine cylinder head and compress the valve spring (a) The plunger cap.
with Valve Spring Compressor Tool MD-998772A. (b) The metering valve.
(6) Install the valve locks and release the tool. (c) The plunger.
(7) Tap the valve spring from side to side with a (d) The check valve assembly.
hammer to ensure that the spring is properly seated (e) The plunger return spring.
at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks. SNAP
(8) Install the engine cylinder head. RING
PLUNGER CAP
HYDRAULIC T A P P E T S
Retain all the components in the same order as re
METERING VALVE
moved.
REMOVAL PLUNGER
(2) Remove the bridge and pivot assemblies and CHECK
VALVE
rocker arms by removing the capscrews at each
SEAT
bridge. Alternately loosen each capscrew, one turn at
a time, to avoid damaging the bridges.
(3) Remove the push rods. CHECK
(4) Remove the intake and engine exhaust mani VALVE
folds (refer to Group 11, Exhaust System and Intake

CHECK
Manifold for the proper procedure). VALVE
(5) Remove the engine cylinder head and gasket. SPRING
(6) Remove the tappets through the push rod open
CHECK
ings in the cylinder block with Hydraulic Valve Tap VALVE
pet Removal/Installation Tool C-4129-A (Fig. 13). RETAINER
DISASSEMBLE PLUNGER
Place the components of each tappet in a separate lo RETURN
SPRING
cation. This will greatly assist in the installation oper
ation. TAPPET
(1) Release the snap ring. BODY J8909-97
(2) Remove the following from the tappet body
(Fig. 14): Fig. 14 Hydraulic Tappet Assembly
CLEANING
Clean the components of each tappet assembly in
cleaning solvent to remove all varnish, gum and
sludge deposits.
INSPECTION
Inspect for indications of scuffing on the side and
base of each tappet body.
Inspect each tappet base for concave wear with a
straightedge positioned across the base. If the base is
concave, the corresponding lobe on the camshaft is
also worn. Replace the camshaft and defective tap
pets.
ASSEMBLY
(1) Install the plunger return spring, check valve
assembly, plunger, metering valve and the plunger Fig. 15 Leak-Down Tester 7980
cap in tappet body. INSTALLATION
(2) Compress the plunger assembly by exerting It is not necessary to charge the tappets with en
force on the plunger cap with the push rod and in gine oil. They will charge themselves within a very
stall snap ring. short period of engine operation.
(1) Dip each tappet in Mopar Engine Oil Supple
LEAK-DOWN TEST
ment, or equivalent.
After cleaning, inspection and assembly, test each
(2) Use Hydraulic Valve Tappet Removal/Installa
tappet for specified leak-down rate tolerance to en
tion Tool C-4129-A to install each tappet in the same
sure zero-lash operation (Fig. 15).
bore from where it was originally removed.
Swing the weighted arm of the hydraulic valve tap
(3) Install the exhaust and intake manifolds (refer
pet tester away from the ram of the Leak-Down
to Group 11, Exhaust System and Intake Manifold
Tester 7980.
for the proper procedure).
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di
(4) Install the engine cylinder head and gasket.
ameter ball bearing on the plunger cap of the tappet.
(5) Install the push rods in their original locations.
(2) Lift the ram and position the tappet (with the
(6) Install the rocker arms and bridge and pivot
ball bearing) inside the tester cup.
assemblies at their original locations. Loosely install
(3) Lower the ram, then adjust the nose of the ram
the capscrews at each bridge.
until it contacts the ball bearing. Do not tighten the
(7) Tighten the capscrews alternately, one turn at
hex nut on the ram.
a time, to avoid damaging the bridges. Tighten the
(4) Fill the tester cup with hydraulic valve tappet
capscrews to 28 N»m (21 ft. lbs.) torque.
test oil until the tappet is completely submerged.
(8) Pour the remaining Mopar Engine Oil Supple
(5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air. ment, or equivalent over the entire valve actuating
When the air bubbles cease, swing the weighted arm assembly. The Mopar Engine Oil Supplement, or
away and allow the plunger to rise to the normal po equivalent must remain with the engine oil for at
sition. least 1 600 km (1,000 miles). The oil supplement
(6) Adjust the nose of the ram to align the pointer need not be drained until the next scheduled oil
with the SET mark on the scale of the tester and change.
tighten the hex nut. (9) Install the engine cylinder head cover.
(7) Slowly swing the weighted arm onto the push
rod. VALVE TIMING
(8) Rotate the cup by turning the handle at the Disconnect the spark plug wires and remove the
base of the tester clockwise one revolution every 2 spark plugs.
seconds. Remove the engine cylinder head cover.
(9) Observe the leak-down time interval from the Remove the capscrews, bridge and pivot assembly,
instant the pointer aligns with the STARt mark on and rocker arms from above the No.l cylinder.
the scale until the pointer aligns with the 0.125 Alternately loosen each capscrew, one turn at a
mark. A normally functioning tappet will require 20- time, to avoid damaging the bridge.
110 seconds to leak-down. Discard tappets with leak- Rotate the crankshaft until the No.4 piston is at
down time interval not within this specification.
J 2.5L ENGINE 9 - 25
top dead center (TDC) on the compression stroke. (4) Install the serpentine drive belt and tighten to
Rotate the crankshaft counterclockwise (viewed the specified tension (refer to Group 7, Cooling Sys
from the front of the engine) 90°. tems for the proper specifications and procedures).
Install a dial indicator on the end of the No.l cyl (5) Connect negative cable to battery.
inder intake valve push rod. Use rubber tubing to se
cure the indicator stem on the push rod. T I M I N G C A S E COVER O I L S E A L R E P L A C E M E N T
Set the dial indicator pointer at zero. This procedure is done with the timing case cover
Rotate the crankshaft clockwise (viewed from the installed.
front of the engine) until the dial indicator pointer (1) Disconnect negative cable from battery.
indicates 0.305 mm (0.012 inch) travel distance (lift). (2) Remove the serpentine drive belt.
The timing notch index on the vibration damper (3) Remove the vibration damper.
(4) Remove the radiator shroud.
should be aligned with the TDC mark on the timing
(5) Remove the oil seal (Fig. 2).
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
the camshaft because of pin failure. A spring pin is
available for service replacement.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpentine drive belt and fan Fig. 2 Timing Case Cover Oil Seal Removal
shroud. (6) Position the replacement oil seal on Timing
(3) Remove the vibration damper retaining bolt Case Cover Alignment and Seal Installation Tool
and washer. 6139 with seal open end facing inward. Apply a light
(4) Use Vibration Damper Removal Tool 8068 to film of Perfect Seal, or equivalent, on the outside di
remove the damper from the crankshaft (Fig. 1). ameter of the seal. Lightly coat the crankshaft with
engine oil.
(7) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal In
stallation Tool 6139 (Fig. 3). Tighten the nut against
the tool until it contacts the cover.
Fig. 1 Vibration Damper Removal Tool 8068

INSTALLATION
(1) With the key in position, align the keyway on
the vibration damper hub with the crankshaft key
and tap the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and Fig. 3 Timing Case Cover Oil Seal Installation
washer. (8) Remove the tools. Apply a light film of engine
(3) Tighten the damper retaining bolt to 108 N»m oil on the vibration damper hub contact surface of
(80 ft. lbs.) torque. the seal.
(9) With the key inserted in the keyway in the (3) Position the timing case cover on the oil pan
crankshaft, install the vibration damper, washer and gasket and the cylinder block.
bolt. Lubricate and tighten the bolt to 108 N-m (80 (4) Insert Timing Case Cover Alignment and Seal
ft. lbs.) torque. Installation Tool 6139 in the crankshaft opening in
(10) Install the serpentine belt and tighten to the the cover (Fig. 5).
specified tension (refer to Group 7, Cooling Systems
TIMING CASE
for the proper specifications and procedures). COVER ALIGNMENT
(11) Install the radiator shroud. A N D SEAL INSTALLATION
(12) Connect negative cable to battery. TOOL
TIMING CASE COVER

REMOVAL
(2) Remove the vibration damper (Fig. 4).
(3) Remove the fan and hub assembly and remove
the fan shroud.
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and J9009-23
generator bracket assembly from the engine cylinder
head and move to one side. Fig. 5 Timing Case Cover Alignment and Seal
(6) Remove the oil pan-to-timing case cover bolts Installation Tool 6139
and timing case cover-to-cylinder block bolts. (5) Install the timing case cover-to-cylinder block
(7) Remove the timing case cover and gasket from and the oil pan-to-timing case cover bolts.
the engine. (6) Tighten the cover-to-block bolts to 7 N-m (60
(8) Pry the crankshaft oil seal from the front of the in. lbs.) torque. Tighten the oil pan-to-cover 1/4 inch
timing case cover (Fig. 4). bolts to 13 N-m (114 in. lbs.) torque. Tighten the oil
VIBRATION TIMING pan-to-cover 5/16 inch bolts to 18 N-m (156 in. lbs.)
DAMPER CASE torque.
PULLEY COVER
(7) Remove the cover alignment tool.
(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) With the key inserted in the keyway in the
crankshaft, install the vibration damper, washer and
OIL
SLINGER bolt. Lubricate and tighten the bolt to 108 N-m (80
ft. lbs.) torque.
(10) Install the A/C compressor (if equipped) and
generator bracket assembly.
(11) Install the engine fan and hub assembly and
shroud.
CRANKSHAFT (12) Install the serpentine drive belt and tighten to
J9009-21
OIL SEAL obtain the specified tension.
Fig. 4 Timing Case Cover Components
CLEANING TIMING CHAIN AND SPROCKETS
Clean the timing case cover, oil pan and cylinder The timing chain tensioner reduces noise and pro
block gasket surfaces. longs timing chain life. In addition, it compensates
for slack in a worn or stretched chain and maintains
INSTALLATION the correct valve timing.
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward REMOVAL
the inside of the cover. Support the cover at the seal - (1) Disconnect negative cable from battery.
area while installing the seal. Force it into position (2) Remove the fan and shroud.
with Seal Installation Tool 6139. (3) Remove the serpentine drive belt.
(2) Position the gasket on the cylinder block. (4) Remove the crankshaft vibration damper.
(5) Remove the timing case cover.
(6) Rotate crankshaft until the "0" timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 6).
TIMING
MARKS
TENSIONER
BLOCK
TENSIONER
LEVER
J9009-27
Fig. 8 Loading Timing Chain Tensioner
(4) Install the camshaft sprocket retaining bolt and
J9009-25
washer. Tighten the bolt to 108 N-m (80 ft. lbs.)
torque.
Fig. 6 Crankshaft/Camshaft Alignment ( 5 ) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
(7) Remove the oil slinger from the crankshaft. sprocket timing mark as shown in Fig. 9. Count the
(8) Remove the camshaft retaining bolt and re number of chain pins between the timing marks of
move the sprockets and chain as an assembly (Fig. both sprockets. There must be 20 pins.
7).
(9) To replace the timing chain tensioner, the oil CAMSHAFT
SPROCKET
pan must be removed.
CAMSHAFT
CHAIN
CRANKSHAFT
SPROCKET
J9009-26
Fig. 7 Camshaft and Crankshaft Sprockets and
Chain CRANKSHAFT
SPROCKET J920f-15
INSTALLATION
(1) Turn the tensioner lever to the unlocked (down) Fig. 9 Verify Sprocket/Chain Installation
position (Fig. 8). (6) Turn the chain tensioner lever to the unlocked
(2) Pull the tensioner block toward the tensioner (down) position (Fig. 8).
lever to compress the spring. Hold the block and turn (7) Install the oil slinger.
the tensioner lever to the lock position (Fig. 8). (8) Replace the oil seal in the timing case cover.
(3) Install the crankshaft/camshaft sprockets and (9) Install the timing case cover and gasket.
timing chain. Ensure the timing marks on the (10) With the key in the keyway on the crank
sprockets are properly aligned (Fig. 6). shaft, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 N-m (80 ft. lbs.)
torque.
(11) Install the fan and shroud. Inspect the bearings for wear.
(12) Connect negative cable to battery. Inspect the distributor drive gear for wear.
If the camshaft appears to have been rubbing
CAMSHAFT against the timing case cover, examine the oil pres
sure relief holes in the rear cam journal. The oil
REMOVAL
pressure relief holes must be free of debris.
WARNING: T H E COOLANT IN A R E C E N T L Y O P E R
INSTALLATION
A T E D ENGINE I S H O T AND P R E S S U R I Z E D . R E
L E A S E T H E P R E S S U R E B E F O R E REMOVING T H E (1) Lubricate the camshaft with Mopar Engine Oil
DRAIN COCK, CAP AND DRAIN P L U G S . Supplement, or equivalent.
(2) Carefully install the camshaft to prevent dam
(1) Disconnect negative cable from battery. age to the camshaft bearings (Fig. 10).
(2) Drain the cooling system. Do not waste reus (3) Install the timing chain, crankshaft sprocket
able coolant. If the solution is clean, drain it into a and camshaft sprocket with the timing marks
clean container for reuse. aligned.
(3) Remove the radiator or radiator/condenser, if (4) Install the camshaft sprocket retaining bolt and
equipped with A/C (refer to Group 7, Cooling System washer. Tighten the bolt to 108 N-m (80 ft. lbs.)
for the proper procedure). torque.
(4) Scribe a mark on the distributor housing in (5) Install the timing case cover with a replace
line with the lip of the rotor. ment oil seal (Fig. 11).
(5) Scribe a mark on the distributor housing near (6) Install the vibration damper.
the clamp and continue the scribe mark on the cyl
inder block in line with the distributor mark. TIMING CAMSHAFT
(6) For ease of installation, note the position of the CASE
COVER
rotor and distributor housing in relation to adjacent
engine components.
(7) Remove the distributor and ignition wires.
(9) Remove the rocker arms, bridges and pivots.
(10) Remove the push rods.
(11) Remove the hydraulic valve tappets from the
engine cylinder head.
(12) Remove the vibration damper.
(14) Remove the timing chain and sprockets.
(15) Remove the camshaft (Fig. 10).
CRANKSHAFT J9009-30
Fig. 11 Timing Case Cover

(7) Install the hydraulic valve tappets.
(8) Install the push rods.
(9) Install the rocker arms, bridges and pivots.
(11) Install the distributor and ignition wires.
(12) Properly position the distributor rotor as fol
lows:
(a) Remove No.l spark plug. Hold your finger
CAMSHAFT over the spark plug hole and rotate the crankshaft
until compression pressure is felt. Slowly continue
CRANKSHAFT to rotate the crankshaft until the timing index on
J9009-31 the vibration damper aligns with the top dead cen
ter (TDC) mark (0° on the timing degree scale). Al
Fig. 10 Camshaft
ways rotate the crankshaft clockwise (the
INSPECTION direction of normal rotation). Do not rotate the
Inspect the cam lobes for wear. crankshaft backward to align the timing
Inspect the bearing journals for uneven wear pat marks.
tern or finish.
J 2.5L ENGINE 9-29
(b) Rotate the oil pump gear so that the gear slot (h) If the distributor is not properly installed, or
on the oil pump shaft is slightly past the 3 o'clock if it is removed later, then the complete installa
position (Fig. 12). A flat blade screwdriver can be tion procedures must be repeated.
used to rotate the gear. FRONT FACE OF
ENGINE BLOCK"
FRONT FACE OF
ENGINE BLOCK
3 O'CLOCK
OIL PUMP POSITION
GEAR SLOT
J9009-32
Fig. 12 Oil Pump Gear Slot Alignment ROTOR POSITION W H E N

PROPERLY INSTALLED
(c) Turn the distributor shaft until the rotor tip J9009-34
points in the direction of No.l terminal in the dis
tributor cap. Turn the rotor 1/8 turn counterclock Fig. 14 Correct Rotor Position
wise past the position of No.l terminal.
(d) With the distributor cap removed, start the (13) Install the radiator or radiator/condenser, if
distributor into the cylinder block with the rotor lo equipped with A/C.
cated at the 5 o'clock position (Fig. 13). (14) Fill the cooling system.
FRONT FACE OF
ENGINE BLOCK
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR

DRAIN COCK WITH THE SYSTEM HOT AND PRES
SURIZED BECAUSE SERIOUS BURNS FROM COOL
ANT CAN OCCUR.
ROTOR (1) Disconnect negative cable from battery.

PRE-POSITIONED (2) Drain the radiator. Do not waste reusable cool
ant. Drain the coolant into a clean container.
5 O'CLOCK (3) Remove the fan and shroud.
APPROX. J9009-33 (4) Disconnect the radiator overflow tube, radiator
Fig. 13 Distributor Rotor Pre-Positioning hoses, automatic transmission fluid cooler pipes (if
equipped).
(e) Slide the distributor shaft down into the en (5) Remove the radiator.
gine. Position the distributor vacuum advance (6) If equipped with air conditioning:
mechanism housing in approximately the same lo
cation as when removed. Align the scribe mark on CAUTION: Do not loosen or disconnect any air con
the distributor housing with the corresponding ditioner system fittings. Move the condenser and
scribe mark on the cylinder block. The rotor should receiver/drier aside as a complete assembly.
align with the position of No.l terminal when the
distributor shaft is down in place. It may be neces (a) Remove the A/C compressor serpentine drive
sary to rotate the oil pump shaft with a long flat- belt idler pulley.
blade screwdriver to engage the oil pump drive (b) Disconnect and remove the generator.
tang. (c) Remove the A/C condenser attaching bolts
(f) Install the distributor holddown clamp and and move the condenser and receiver/drier assem
bolt, but do not tighten the bolt. bly up and out of the way.
(g) When the distributor is fully engaged in its
(7) Remove the serpentine drive belt.
correct location, the rotor should be at the 6 o'clock
(8) Remove the crankshaft vibration damper.
position (Fig. 14).
(9) Remove the timing case cover. Clean the gas CAUTION: Cover the opened oil pan area to prevent
ket material from the cover. metal chips from entering the pan.
(10) Rotate crankshaft until the crankshaft
sprocket timing mark is closest to and on the center (17) Drill into the pin center with a 4 mm (5/32
line with the camshaft sprocket timing mark (Fig. inch) drill bit.
15). (18) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled, bab
bitt-lined bearings that are pressed into the cylinder
block and then line reamed. The camshaft bearing
bores and bearing diameters are not the same size.
They are stepped down in 0.254 mm (0.010 inch) in
crements from the front bearing (largest) to the rear
bearing (smallest). This permits easier removal and
installation of the camshaft. The camshaft bearings
are pressure lubricated.
It is not advisable to attempt to replace cam
shaft bearings unless special removal and instal
J9009-25 lation tools are available.
Camshaft end play is maintained by the load
Fig. 15 Timing Chain Alignment placed on the camshaft by the oil pump and distrib
(11) Remove camshaft sprocket retaining bolt. utor drive gear. The helical cut of the gear holds the
(12) Remove the crankshaft oil slinger. camshaft sprocket thrust face against the cylinder
(13) Remove the sprockets and chain as an assem block face.
bly (Fig. 16).
INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install the camshaft sprocket, crankshaft
sprocket and timing chain with the timing marks
CHAIN aligned (Fig. 15).
(5) To verify correct installation of the timing
sprocket timing mark as shown in Fig. 17. Count the
number of chain pins between the timing marks of
both sprockets. There must be 20 pins.
(6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket bolt to 108 N»m
Fig. 16 Camshaft and Crankshaft Sprocket and (8) Check the valve timing.
Chain (9) Coat both sides of the replacement timing case
CAUTION: The following procedural step must be cover gasket with gasket sealer. Apply a 3 mm (1/8
accomplished to prevent the camshaft from damag inch) bead of Mopar Silicone Rubber Adhesive Seal
ing the rear camshaft plug during pin installation. ant, or equivalent to the joint formed at the timing
case cover and cylinder block.
(14) Inspect the damaged camshaft pin. (10) Position the timing case cover on the oil pan
(15) If the pin is a spring-type pin, remove the bro gasket and the cylinder block.
ken pin by inserting a self-tapping screw into the pin (11) Place Timing Case Cover Alignment and Seal
and carefully pulling the pin from the camshaft. Installation Tool 6139 in the crankshaft opening of
(16) If the pin is a dowel-type pin, center-punch it. the cover (Fig. 18).
Ensure the exact center is located when center- (12) Install the timing case cover-to-cylinder block
punching the pin. bolts. Install the oil pan-to-timing case cover bolts.
CAMSHAFT (c) Install the A/C condenser and receiver/drier
SPROCKET assembly.
(18) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(19) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(20) Install the fan and shroud.
OIL PAN
REMOVAL
(3) Remove the oil pan drain plug and drain the
engine oil.
(4) Disconnect the exhaust pipe at the engine ex
haust manifold.
CRANKSHAFT (5) Disconnect the exhaust hanger at the catalytic
SPROCKET J9209-15
converter and lower the pipe.
Fig. 17 Verify Crankshaft/Camshaft Installation (6) Remove the engine starter motor.
(7) Remove the flywheel/torque converter housing
TIMING CASE access cover.
COVER ALIGNMENT
(8) Position a jack stand directly under the engine
A N D SEAL INSTALLATION.
TOOL vibration damper.
(9) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(10) Remove the engine mount through bolts.
(11) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(12) Remove the oil pan bolts. Carefully remove
the oil pan and gasket.
CLEANING
Clean the block and pan gasket surfaces.
J9009-23 INSTALLATION
(1) Fabricate 4 alignment dowels from 1 1/2 x 1/4
Fig. 18 Timing Case Cover Alignment and Seal inch bolts. Cut the head off the bolts and cut a slot
Installation Tool 6139 into the top of the dowel. This will allow easier in
(13) Tighten the cover-to-block bolts to 7 N-m (60 stallation and removal with a screwdriver (Fig. 1).
in. lbs.) torque. Tighten the oil pan-to-cover 1/4 inch 1 1/2" x 1/4" BOLT
bolts to 13 N-m (114 in. lbs.) torque. Tighten the oil /
pan-to-cover 5/16 inch bolts to 18 N-m (156 in. lbs.)
torque.
(14) Remove the cover alignment tool and install a
replacement oil seal into the cover. DOWEL
(15) Install the vibration damper on the crank
shaft.
(16) Lubricate and tighten the damper bolt to 108
SLOT
E J9209-6
(17) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive Fig. 1 Fabrication of Alignment Dowels
belt idler pulley.
(b) Install the generator.
9 - 32 2.5L ENGINE
(2) Install two dowels in the timing case cover. In (11) Install the engine starter motor.
J
stall the other two dowels in the cylinder block (Fig. (12) Connect the exhaust pipe to the hanger and to
2). the engine exhaust manifold.
(13) Install the oil pan drain plug (Fig. 3). Tighten
the plug to 41 N-m (30 ft. lbs.) torque.
(16) Fill the oil pan with engine oil to the specified
level.
WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT STAND IN A DI
RECT L I N E WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR T H E PULLEYS, BELTS OR FAN. DO
NOT W E A R LOOSE CLOTHING.
OIL PUMP
Fig. 2 Position of Dowels in Cylinder Block The positive-displacement gear-type oil pump is
driven by the distributor shaft, which is driven by a
(3) Slide the one-piece gasket over the dowels and gear on the camshaft. Oil is siphoned into the pump
onto the block and timing case cover.
through an inlet tube and strainer assembly that is
(4) Position the oil pan over the dowels and onto pressed into the pump body.
the gasket.
The pump incorporates a nonadjustable pressure
(5) Install the 1/4 inch oil pan bolts. Tighten these relief valve to limit maximum pressure to 517 kPa
bolts to 13 N-m (114 in. lbs.) torque. Install the 5/16 (75 psi). In the relief position, the valve permits oil
inch oil pan bolts (Fig. 3). Tighten these bolts to 18
to bypass through a passage in the pump body to the
N-m (156 in. lbs.) torque.
inlet side of the pump.
Oil pump removal or replacement will not affect
the distributor timing because the distributor drive
gear remains in mesh with the camshaft gear.
REMOVAL
(1) Drain the engine oil.
(2) Remove the oil pan.
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
4).
CAUTION: If the oil pump i s not to be serviced, do

not disturb position of oil inlet tube and strainer as
sembly in pump body. If the tube i s moved within
the pump body, a replacement tube and strainer as
sembly must be installed to assure an airtight seal.
Fig. 3 Position of 5/16 inch Oil Pan Bolts
(6) Remove the dowels. Install the remaining 1/4 DISASSEMBLE
inch oil pan bolts. Tighten these bolts to 13 N-m (114 (1) Remove the cover from the pump body.
in. lbs.) torque. (2) Check the following clearances:
(7) Lower the engine until it is properly located on
the engine mounts. GEAR END CLEARANCE MEASUREMENT
(8) Install the through bolts and tighten the nuts PREFERRED METHOD:
to 65 N-m (48 ft. lbs.) torque. (a) Place a strip of Plastigage across the full
(9) Lower the jack stand and remove the piece of width of each gear.
wood. (b) Install the pump cover and tighten the bolts
(10) Install the flywheel/torque converter housing to 8 N-m (70 in. lbs.) torque.
access cover.
2.5L ENGINE S - 33
J A L T E R N A T I V E METHOD:
(a) Place a straightedge across the ends of the
gears and the pump body.
(b) Select a feeler gauge that fits snugly but
freely between the straightedge and the pump body
(Fig. 6).
(c) Correct clearance by this method is 0.051-
0.152 mm with 0.051 mm preferred (0.002-0.006
inch with 0.002 inch preferred).
(d) If gear end clearance is excessive, replace the
oil pump assembly.
STRAINER ATTACHING
ASSEMBLY BOLTS J8909-119
Fig. 4 Oil Pump Assembly
(c) Remove the pump cover and determine the
amount of clearance by measuring the width of
compressed Plastigage with scale on the Plastigage
envelope (Fig. 5).
(d) Correct clearance by this method is 0.051-
0.152 mm with 0.051 mm preferred (0.002-0.006 Fig. 6 Gear End Clearance
inch with 0.002 inch preferred). Measurement—Alternative Method
(e) If gear end clearance is excessive, replace the GEAR-TO-BODY CLEARANCE MEASUREMENT
oil pump assembly. (a) Measure the gear-to-body clearance with both
OIL PUMP gears in place. Insert a feeler gauge between the
GEAR gear tooth and the inner wall of the pump body di
rectly opposite the point of gear mesh. Select a
feeler gauge which fits snugly but freely. Rotate
gears to measure each tooth-to-body clearance in
this manner (Fig. 7).
(b) Correct clearance is 0.051-0.102 mm with
0.051 mm preferred (0.002-0.004 inch with 0.002
inch preferred).
(c) If the gear-to-body clearance is more than
specified, replace oil pump.
DISASSEMBLE (CONT.J
(3) Remove the cotter pin and slide the spring re
tainer, spring and oil pressure relief valve plunger
out of the pump body.
(4) Inspect for binding condition during disassem
bly. Clean or replace as necessary.
(5) The oil inlet tube and strainer assembly must
be moved to allow removal of the relief valve.
STRIP OF PLASTIGAGE J8909-120
ASSEMBLE
Fig. 5 Gear End Clearance Measurement—Preferred Two relief valve plunger sizes (standard and over
Method size) are available. The oversize plunger diameter is
0.254 mm (0.010 inch).
9 - 34 2,§L ENGINE J
(6) Apply a thin bead of Mopar Gasket Maker, or

equivalent, to the top of the pump housing.
(7) Install the oil pump cover. Tighten the cover
bolts to 8 N«m (70 in. lbs.) torque.
INSTALLATION
(1) Install the oil pump on the cylinder block using
a replacement gasket. Tighten the short bolt to 14
N«m (10 ft. lbs.) torque and the long bolt to 23 N«m
(2) Install the oil pan.
(3) Fill the oil pan with oil to the specified level.
OIL PUMP PRESSURE

The MINIMUM oil pump pressure is 89.6 kPa (13
psi) at 600 rpm. The MAXIMUM oil pump pressure
is 255-517 kPa (37-75 psi) at 1600 rpm or more.
PISTONS AND CONNECTING RODS

J8909-122 REMOVAL
Fig. 7 Gear-to-Rody Clearance Measurement
(1) Install the oil pressure relief valve plunger, (3) Remove the push rods.
spring, retainer and cotter pin. (4) Remove the engine cylinder head.
(2) If the position of the inlet tube in the pump (5) Position the pistons one at a time near the bot
body has been disturbed, install a replacement inlet tom of the stroke. Use a ridge reamer to remove the
tube and strainer assembly. Apply a light film of ridge from the top end of the cylinder walls. Use a
Permatex No.2 sealant, or equivalent, around the
protective cloth to collect the cuttings.
end of the tube. Use Oil Pump Inlet Tube Installa
tion Tool 7624 to drive the inlet tube into the body
(7) Drain the engine oil.
(Fig. 8). Be sure the support bracket is properly
aligned. (8) Remove the oil pan and gasket.
(9) Remove the connecting rod bearing caps and
inserts. Retain in the same order as removed. The
connecting rods and caps are stamped with the corre
sponding cylinder number (Fig. 1).
CONNECTING
ROD CAP
Fig. 8 Inlet Tube Installation Tool 7624

(3) Install the idler gear and drive gear assembly.
(4) Spin the drive gear shaft to ensure a binding CONNECTING ROD J90Q9-40
condition does not exist before installing the oil
pump. Fig. 1 Stamped Connecting Rods and Caps
(5) To self-prime the oil pump, fill pump with pe (10) Lower the vehicle until it is about 2 feet from
troleum jelly before installing the oil pump cover. the floor.
DO NOT use grease.
2 J L ENGINE 9 - 35
J
CAUTION; Ensure that the c o n n e c t i n g rod bolts DO UPPER MATING EDGES
NOT scratch t h e crankshaft journals o r cylinder
walls. Short p i e c e s o f rubber h o s e , slipped o v e r t h e
rod bolts will provide protection during removal.
(11) Have an assistant push the piston/connecting

rod assemblies up and through the top of the cylinder
bores (Fig. 2).
PISTON^ ^ ^
Fig. 3 Connecting Rod Bearing Inspection

ABNORMAL CONTACT AREA
CAUSED BY LOCKING TABS NOT
FULLY SEATED OR BEING BENT
J8909-126
Fig. 2 Removal of Connecting Rod and Piston
Assembly J8909-128
INSPECTION-CONNECTING ROD Fig. 4 Locking Tab Inspection
CONNECTING ROD BEARINGS

Inspect the connecting rod bearings for scoring and
bent alignment tabs (Figs. 3 and 4). Check the bear
ings for normal wear patterns, scoring, grooving, fa
tigue and pitting (Fig. 5). Replace any bearing that
shows abnormal wear. LOWER
Inspect the connecting rod journals for signs of
scoring, nicks and burrs. J8909-129
CONNECTING RODS Fig. 5 Scoring Caused by Insufficient Lubrication or

Misaligned or bent connecting rods can cause ab by Damaged Crankshaft Pin Journal
normal wear on pistons, piston rings, cylinder walls, (3) Lubricate the upper bearing insert and install
connecting rod bearings and crankshaft connecting in connecting rod.
rod journals. If wear patterns or damage to any of (4) Use piston ring compressor to install the rod
these components indicate the probability of a mis and piston assemblies. The oil squirt holes in the
aligned connecting rod, inspect it for correct rod rods must face the camshaft. The arrow on the piston
alignment. Replace misaligned, bent or twisted con crown should point to the front of the engine (Fig. 6).
necting rods. Verify that the oil squirt holes in the rods face the
camshaft and that the arrows on the pistons face the
BEARING-TO-JOURNAL CLEARANCE front of the engine.
(1) Wipe the oil from the connecting rod journal. (5) Install the lower bearing insert in the bearing
(2) Use short rubber hose sections over rod bolts cap. The lower insert must be dry. Place strip of
during installation. Plastigage across full width of the lower insert at the
I - 38 2 . 5 L ENGINE J
ment bearing inserts are stamped on the backs of the

inserts. Measure the clearance as described in the
previous steps.
(10) The clearance is measured with a pair of
0.0254 mm (0.001 inch) undersize bearing inserts in
stalled. This will determine if two 0.0254 mm (0.001
inch) undersize inserts or another combination is
needed to provide the correct clearance (refer to Con
necting Rod Bearing Fitting Chart).
FOR EXAMPLE: If the initial clearance was
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) un
dersize inserts would reduce the clearance by 0.025
J9009-41 mm (0.001 inch). The clearance would be 0.002 inch
and within specification. A 0.051 mm (0.002 inch)
Fig. 6 Rod and Piston Assembly Installation
undersize insert would reduce the initial clearance
center of bearing cap. Plastigage must not crumble an additional 0.013 mm (0.0005 inch). The clearance
in use. If brittle, obtain fresh stock. would then be 0.038 mm (0.0015 inch).
(6) Install bearing cap and connecting rod on the (11) Repeat the Plastigage measurement to verify
journal and tighten nuts to 45 N*m (33 ft. lbs.) your bearing selection prior to final assembly.
torque. Do not rotate crankshaft. Plastigage will (12) Once you have selected the proper insert, in
smear, resulting in inaccurate indication. stall the insert and cap. Tighten the connecting rod
(7) Remove the bearing cap and determine amount bolts to 45 N*m (33 ft. lbs.) torque.
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 7). Refer to En SIDE CLEARANCE MEASUREMENT
gine Specifications for the proper clearance. Plasti Slide snug-fitting feeler gauge between the con
gage should indicate the same clearance across necting rod and crankshaft journal flange. Refer to
the entire width of the insert. If the clearance Engine Specifications for the proper clearance. Re
varies, it may be caused by either a tapered place the connecting rod if the side clearance is not
journal, bent connecting rod or foreign material within specification.
trapped between the insert and cap or rod.
PISTON FITTING
PLASTIGAGE
SCALE
MICROMETER METHOD
(1) Measure the inside diameter of the cylinder
bore at a point 58.725 mm (2-5/16 inches) below top
of bore.
(2) Measure outside diameter of the piston. Be
cause pistons are cam ground, measure at right an
gle to piston pin at center line of pin (Fig. 8).
The difference between cylinder bore diameter and
piston diameter is piston-to-bore clearance.
FEELER GAUGE METHOD

(1) Remove the rings from the piston.
(2) Insert a long 0.025 mm (0.001 inch) feeler
gauge into the cylinder bore.
(3) Insert the piston, top first, into cylinder bore
Fig. 7 Measuring Bearing Clearance with Plastigage alongside the feeler gauge. With entire piston in
(8) If the correct clearance is indicated, replace serted into cylinder bore, the piston should not bind
ment of the bearing inserts is not necessary. Remove against feeler gauge.
the Plastigage from crankshaft journal and bearing (4) Repeat steps with a long 0.051 mm (0.002 inch)
insert. Proceed with installation. feeler gauge. The piston should bind.
(9) If bearing-to-journal clearance exceeds the spec (5) If the piston binds on 0.025 mm (0.001 inch)
ification, install a pair of 0.0254 mm (0.001 inch) un feeler gauge, the piston is too large or cylinder bore
dersize bearing inserts. All the odd size inserts must is too small. If the piston does not bind on 0.051 mm
(0.002 inch) feeler gauge, the piston is too small for
be on the bottom. The sizes of the service replace
cylinder bore. Pistons up to 0.102 mm (0.004 inch)
CONNECTING ROD BEARING FITTING CHART
Corresponding Connecting Rod

Crankshaft Main Bearing Journal Bearing Insert Color Code
Color Code a n d Diameter
Upper Insert Size Lower I n s e r t Size
Yellow—53.2257-53.2079 mm Yellow—Standard Yellow—Standard

(2.0955-2.0948 in.)
Orange—53.2079-53.1901 mm Blue—Undersize
(2.0948-2.0941 in.) Yel low—Standard
0.025 mm (0.001 in.)
0.0178 mm (0.0007 in.) Undersize
Black—53.1901-53.1723 mm Blue—Undersize Blue—Undersize

(2.0941-2.0933 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Red—52.9717-52.9539 mm Red—Undersize Red—Undersize

(2.0855-2.0848 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
J9209-49
GROOVE HEIGHT (2) Apply force to a piloted driver and press the
pin completely out of the connecting rod and piston
A 2.0193-2.0447 mm (0.0795-0.0805 in) assembly (Fig. 9). Note position of the pin through
B 4.7752-4.8133 mm (0.1880-0.1895 in)
the gauge window of removal support tool.
GROOVE DIAMETER PILOTED I «|

DRIVER I^JI PILOTED n
D- E 87.78-87.90 mm 456-3.461 in) DRIVER 1
87.50-87.75 mm fl:445-3.455 in)
F
u
PILOT
MEASURE PISTON
AT THIS AREA SUPPORT f&
FOR FITTING
J8909-136
Fig. 8 Piston Dimensions

undersize may be enlarged by knurling or shot-peen- GAUGE
WINDOW
ing. Replace pistons that are 0.102 mm (0.004 inch) SUPPORT J8909-133
or more undersize.
Fig. 9 Piston Pin Removal/installation
PISTON PIN
INSPECTION
REMOVAL (1) Inspect the piston pin and pin bore in the con
Piston pins are press-fitted into the connecting rods necting rod for nicks and burrs. Remove as neces
and require no locking device. sary. Never reuse a piston pin after it has been
(1) Position the piston and connecting rod assem installed in and removed from a connecting rod.
bly on an arbor press.
(2) With the pin removed from the piston and con (2) Measure the ring side clearance with a feeler
necting rod, clean and dry piston pin bores and the gauge fitted snugly between the ring land and ring
replacement piston pin. (Fig. 11). Rotate the ring in the groove. It must move
(3) Position the piston so that the pin bore is in freely around circumference of the groove.
vertical position. Insert the pin in bore. At room tem
perature, the replacement pin should slide com îlllmftfrs Inches
0.025-0.081 0.001-0.0032
N o . 1 Compression
pletely through the pin bore in piston by force of (0.043 Preferred) (0.0017 Preferred)
gravity. 0.001-0.0032
N o . 2 Compression 0.025-0.081
(4) Replace piston if pin jams in the pin bore. (0.043 Preferred) (0.0017 Preferred)
Oil Control 0.025-0.241 0.001-0.0095

INSTALLATION (0.08 Preferred) (0.003 Preferred)
(1) Insert the piston pin pilot through the piston
and connecting rod pin bores. Ensure that the arrow
on the piston crown is pointing up (Fig. 10).
(2) Position the pin pilot, piston and connecting
rod on a support with the squirt hole of the connect
ing rod to the left-hand side (Fig. 10).
(3) Insert piston pin through the upper piston pin FEELER
GAUGE
bore and into the connecting rod pin bore.
(4) Position the piloted driver inside the piston pin
(Fig. 9).
(5) Using an arbor press, press the piston pin
through the connecting rod and piston bores until pin
pilot indexes with mark on the support. The piston
pin requires a 8 900 N (2,000 pounds) press-fit. If lit E8909-402
tle effort is required to install piston pin in a con
necting rod, or if the rod moves laterally on the pin, Fig. 11 Ring Side Clearance Measurement
the connecting rod must be replaced. (3) Place ring in the cylinder bore and push down
(6) Remove the piston and connecting rod assembly with inverted piston to position near lower end of the
from the press. The pin should be centered in the ring travel. Measure ring gap with a feeler gauge fit
connecting rod (±0.792 mm or ±0.0312 inch) and ting snugly between ring ends (Fig. 12). The correct
float in the piston pin bore. compression ring end gap is 0.25-0.51 mm (0.010-
CONNECTING 0.020 inch). The correct oil control ring end gap is
ROD 0.381-1.397 mm (0.015-0.055 inch).
PISTON FEELER GAUGE
SQUIRT
HOLE
J9009-44
Fig. 10 Correct Alignment—Piston and Connecting

J9009-45
Rod
PISTON RING FITTING Fig. 12 Ring Gap Measurement
(1) Carefully cle^n the carbon from all ring
grooves. Oil drain openings in the oil ring groove and (4) Position the ring gaps and install piston rings
pin boss must be clear. Do not remove metal from (Fig. 13).
the grooves or lands. This will change ring-to-groove (5) Install the oil control rings according to in
clearances and will damage the ring-to-land seating. structions in the package. It is not necessary to use a
TOP COMPRESSION RING TOP COMPRESSION
RING
BOTTOM
COMPRESSION
RING
TOP OIL
CONTROL RAIL
SECOND
OIL RAIL COMPRESSION
EXPANDER RING
BOTTOM OIL
CONTROL RAIL
IMAGINARY LINE
THROUGH CENTER
OF PISTON SKIRT
IMAGINARY LINE J 8909-139
PARALLEL TO
PISTON PIN Fig. 14 Compression Ring Location
SECOND COMPRESSION RING
RING GAP POSITION M^Y (BLACK CAST IRON)
VARY ± 2 0 ° FROM
POSITION ILLUSTRATED CHAMFER
J9109-209
Fig. 13 Ring Gap Position

tool to install the upper and lower rails. Insert ex
pander ring first, then side rails
(6) The two compression rings are different and
cannot be interchanged (Fig. 14). The top ring is a
moly ring (the scraping edge is gray in color). The
second ring is a black cast iron ring (the scraping
TWO
edge is black in color when new).
(7) The compression rings can be identified by a DOTS J9009-46
chamfer of either the top or bottom inside edge (Fig.
15). The rings may also be identified by 1 or 2 dots Fig. 15 Second Compression Ring Identification
on the top surface of the ring.
(8) The second compression ring (black cast iron)
has a chamfer on the BOTTOM of the inside edge
(Fig. 15). This ring may also have 2 dots located on
the top surface.
(9) Using a ring installer, install the second com
pression ring with the chamfer facing down (Fig. 16).
The dots will be facing up.
(10) The top compression ring (the scraping edge is
gray in color) has a chamfer on the TOP of the inside
edge (Fig. 17). This ring may also have 1 dot located
on the top surface.
COMPRESSION
(11) Using a ring installer, install the top ring RING
with the chamfer facing up. The dot will be facing RING EXPANDER J9009-47
up. RECOMMENDED
(12) Position the ring end gaps on the piston.
Fig. 16 Compression Ring Installation
9 - 40 2 J L ENGINE
bearing and the journal. In production, the select fit

J
is obtained by using various-sized, color-coded bear
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
The rod journal is identified during the engine pro
duction by a color-coded paint mark on the adjacent
cheek or counterweight toward the flange (rear) end
of the crankshaft. The color codes used to indicate
journal sizes are listed in the Connecting Rod Bear
ing Fitting Chart.
When required, upper and lower bearing inserts of
different sizes may be used as a pair (refer to Con
J90QM8 necting Rod Bearing Fitting Chart). A standard size
insert is sometimes used in combination with a 0.025
Fig. 17 Top Compression Ring identification mm (0.001 inch) undersize insert to reduce clearance
CLEANING 0.013 mm (0.0005 inch).
Clean the cylinder bores thoroughly. Apply a light
CAUTION: Do not intermix bearing caps. Each con
film of clean engine oil to the bores with a clean lint-
necting rod and bearing cap are stamped with the
free cloth.
cylinder number. The stamp is located on a ma
INSTALLATION chined surface adjacent to the oil squirt hole that
(1) Install the piston rings on the pistons if re faces the camshaft side of the cylinder block.
moved.
(6) Install the connecting rod bearing caps and in
(2) Lubricate the piston and rings with clean en
serts in the same positions as removed.
gine oil.
CAUTION: Verify that the oil squirt holes in the rods
CAUTION: Ensure that connecting rod bolts do not face the camshaft and that the arrows on the pis
scratch the crankshaft journals or cylinder walls. tons face the front of the engine.
Short pieces of rubber hose slipped over the con
necting rod bolts will provide protection during in (7) Install the oil pan and gaskets as outlined in
stallation. the installation procedure.
(3) Use a piston ring compressor to install the con (9) Install the engine cylinder head, push rods,
necting rod and piston assemblies through the top of rocker arms, bridges, pivots and engine cylinder head
the cylinder bores (Fig. 18). cover.
(4) Ensure the arrow on the piston top points to (10) Fill the crankcase with engine oil.
the front of the engine (Fig. 18).
CRANKSHAFT MAIN BEARINGS
REMOVAL
(2) Remove the spark plugs.
(4) Remove the oil pan and oil pump.
(5) Remove only one main bearing cap and lower
insert at a time (Fig. 1).
(6) Remove the lower insert from the bearing cap.
(7) Remove the upper insert by LOOSENING (DO
NOT REMOVE) all of the other bearing caps. Now
insert a small cotter pin tool in the crankshaft jour
J9009-41 nal oil hole. Bend the cotter pin as illustrated to fab
ricate the tool (Fig. 2). With the cotter pin tool in
place, rotate the crankshaft so that the upper bear
(5) Raise the vehicle. ing insert will rotate in the direction of its locking
Each bearing insert is fitted to its respective jour tab. Because there is no hole in the No.3 main jour
nal to obtain the specified clearance between the nal, use a tongue depressor or similar soft-faced tool
CONNECTING UPPER
INSERT NO WEAR IN
ROD JOURNAL
T H I S AREA
L O W AREA
IN BEARING
LINING
LOWER
INSERT
HEAVIER W E A R
PATTERN O N
L O W E R INSERT J9009-90
Fig. 3 Main Bearing Wear Patterns

imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 3).
If any of the crankshaft journals are scored,
MAIN BEARING CAPS J8909-144 remove the engine for crankshaft repair.
Inspect the back of the inserts for fractures, scrap
Fig. 1 Removing Main Rearing Caps and Lower
inserts ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
to remove the bearing insert (Fig. 2). After moving Replace all damaged or worn bearing inserts.
the insert approximately 25 mm (1 inch), it can be
removed by applying pressure under the tab. FITTING (CRANKSHAFT INSTALLED)
(8) Using the same procedure described above, re The main bearing caps, numbered (front to rear)
move the remaining bearing inserts one at a time for from 1 through 5 have an arrow to indicate the for
inspection. ward position. The upper main bearing inserts are
COTTER
grooved to provide oil channels while the lower in
PIN serts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
for engine production.
BEARING The main bearing journal size (diameter) is identi
INSERT fied by a color-coded paint mark on the adjacent
cheek. The rear main journal, is identified by a color-
coded paint mark on the crankshaft rear flange.
different sizes may be used as a pair. A standard size
mm (0.001 inch) undersize insert to reduce the clear
ance by 0.013 mm (0.0005 inch). Never use a pair
of bearing inserts with greater than a 0.025 mm
J9009-49
(0.001 inch) difference in size (Fig. 4).
Fig. 2 Removing Upper Inserts When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block)
INSPECTION or all on the bottom (in main bearing cap).
Wipe the inserts clean and inspect for abnormal Once the bearings have been properly fitted, pro
wear patterns and for metal or other foreign material ceed to Crankshaft Main Bearing—Installation.
If the specified clearance is indicated and there are
Insert Correct incorrect
no abnormal wear patterns, replacement of the bear
Upper Standard Standard ing inserts is not necessary. Remove the Plastigage
from the crankshaft journal and bearing insert. Pro
ceed to Crankshaft Main Bearing—Installation.
0 . 0 5 1 mm ( 0 . 0 0 2 in.)
If the clearance exceeds specification, install a pair
0 . 0 2 5 mm ( 0 . 0 0 1 in.)
Lower
Undersize Undersize of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ
ous steps.
The clearance indicated with the 0.025 mm (0.001
J9109-179
inch) undersize insert pair installed will determine if
Fig. 4 Bearing Insert Pairs this insert size or some other combination will pro
vide the specified clearance.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT FOR EXAMPLE: If the clearance was 0.0762 mm
INSTALLED)
(0.003 inch) originally, a pair of 0.0254 mm (0.001
When using Plastigage, check only one bearing
inch) undersize inserts would reduce the clearance by
clearance at a time.
0.0254 mm (0.001 inch). The clearance would then be
Install the grooved main bearings into the cylinder
0.0508 mm (0.002 inch) and within the specification.
block and the non-grooved bearings into the bearing
A 0.051 mm (0.002 inch) undersize bearing insert
caps.
and a 0.0254 mm (0.001 inch) undersize insert would
Install the crankshaft into the upper bearings dry.
reduce the original clearance an additional 0.0127
Place a strip of Plastigage across full width of the
mm (0.0005 inch). The clearance would then be
crankshaft journal to be checked.
0.0381 mm (0.0015 inch).
Install the bearing cap and tighten the bolts to 108
N*m (80 ft. lbs.) torque. CAUTION: Never use a pair of inserts that differ
DO NOT rotate the crankshaft. This will cause more than one bearing size as a pair.
the Plastigage to shift, resulting in an inaccurate
reading. Plastigage must not be permitted to FOR EXAMPLE: Do not use a standard size up
crumble. If brittle, obtain fresh stock. per insert and a 0.051 mm (0.002 inch) undersize
Remove the bearing cap. Determine the amount of lower insert.
clearance by measuring the width of the compressed If the clearance exceeds specification using a pair
Plastigage with the scale on the Plastigage envelope of 0.051 mm (0.002 inch) undersize bearing inserts,
(Fig. 5). Refer to Engine Specifications for the proper measure crankshaft journal diameter with a mi
clearance. crometer. If the journal diameter is correct, the
crankshaft bore in the cylinder block may be mis
PLASTIGAGE
SCALE aligned, which requires cylinder block replacement
or machining to true bore.
If journals 1 through 5 diameters are less than
63.4517 mm (2.4981 inches), replace crankshaft or
grind crankshaft down to accept the appropriate un
dersize bearing inserts.
Once the proper clearances have been obtained,
proceed to Crankshaft Main Bearing—Installation.
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT

REM0WED)
Remove the crankshaft from the cylinder block (re
fer to Cylinder Block - Disassemble).
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90°
Fig. 5 Measuring Bearing Clearance with Plastigage apart at each end of the journal.
Plastigage should indicate the same clearance The maximum allowable taper and out of round is
across the entire width of the insert. If clearance var 0.013 mm (0.0005 inch). Compare the measured di
ies, it may indicate a tapered journal or foreign ma ameter with the journal diameter specification (Main
terial trapped behind the insert. Bearing Fitting Chart). Select inserts required to ob
tain the specified bearing-to-journal clearance.
MAIN BEARING FITTING CHART
Crankshaft Bearing Insert Color Code

Color Cod* and Diameter
(Journal Size) Upper Insert Size Lower Insert Size
Yellow - 63.5025-63.4898 mm Yellow - Standard Yellow - Standard

(2.5001-2.4996 in.)
(Standard)
Orange - 63.4898-63.4771 mm Yellow - Standard Blue - 0.025 mm

(2.4996-2.4991 in.) Undersize (0.001 in.)
(0.0005 Undersize)
Black - 63.4771-63.4644 mm Blue - 0.025 mm Blue - 0.025 mm

(2.4991-2.4986 in.) Undersize (0.001 in.) Undersize (0.001 in.)
(0.001 Undersize)
Green - 63.4644-63.4517 mm Blue - 0.025 mm Green - 0.051 mm

(0.0015 Undersize)
Red - 63.2485-63.2358 mm Red - 0.254 mm Red - 0.254 mm

0.010 Undersize)
J9209-5O
Once the proper clearances have been obtained, (d) Pry the crankshaft forward and backward.
proceed to Crankshaft Main Bearing—Installation. Note the dial indicator readings. End play is the
difference between the high and low measurements
INSTALLATION (Fig. 6). Correct end play is 0.038-0.165 mm
(1) Lubricate the bearing surface of each insert (0.0015-0.0065 inch). The desired specifications are
with engine oil. 0.051-0.064 mm (0.002-0.0025 inch).
(2) Loosen all the main bearing caps. Install the
DIAL
main bearing upper inserts. INDICATOR
(3) Install the lower bearing inserts into the main
bearing caps.
(4) Install the main bearing cap(s) and lower in-
sert(s).
(5) Tighten the bolts of caps 1, 3, 4 and 5 to 54
N»m (40 ft. lbs.) torque. Now tighten these bolts to 95
N»m (70 ft. lbs.) torque. Finally, tighten these bolts
(6) Push the crankshaft forward and backward.
Load the crankshaft front or rear and tighten cap
bolt No.2 to 54 N*m (40 ft. lbs.) torque. Then tighten
to 95 Nnn (70 ft. lbs.) torque and finally tighten to
108 N*m (80 ft. lbs.) torque. J9009-1
(7) Rotate the crankshaft after tightening each
main bearing cap to ensure the crankshaft rotates Fig. 6 Crankshaft End Play Measurement
freely.
(e) If end play is not within specification, inspect
(8) Check crankshaft end play. Crankshaft end
crankshaft thrust faces for wear. If no wear is ap
play is controlled by the thrust bearing which is
parent, replace the thrust bearing and measure end
flange and installed at the No.2 main bearing posi play. If end play is still not within specification, re
tion. place the crankshaft.
(a) Attach a magnetic base dial indicator to the If the crankshaft was removed, install the crank
cylinder block at either the front or rear of the en shaft into the cylinder block (refer to Cylinder Block
gine. - Assemble). i
(b) Position the dial indicator rod so that it is (9) Install the oil pan.
parallel to the center line of the crankshaft. (10) Install the drain plug. Tighten the plug to 41
(c) Pry the crankshaft forward, position the dial N-m (30 ft. lbs.) torque.
indicator to zero. (11) Lower the vehicle.
9 - 44 2 J L ENGINE J
(12) Install the spark plugs. Tighten the plugs to (2) Remove the water pump from the cylinder
37 N-m (27 ft. lbs.) torque. block.
(13) Fill the oil pan with engine oil to the full (3) Remove the distributor from the cylinder block.
mark on the dipstick level. (4) Remove the vibration damper.
(14) Connect negative cable to battery. (5) Remove the timing case cover and lay the cover
upside down.
REAR MAIN OIL SEALS (6) Position a drift punch into the slot in the back
of the cover and tap the old seal out.
REMOVAL
(1) Remove the flywheel or converter drive plate. (7) Remove the timing chain bumper.
Discard the old bolts. (8) Remove the oil slinger from crankshaft.
(2) Pry out the seal from around the crankshaft (9) Remove the camshaft retaining bolt and re
flange (Fig. 7). move the sprockets and chain as an assembly.
(10) Remove the camshaft.
(11) Remove the oil pan and gasket.
(12) Remove the timing chain tensioner.
(13) Remove the front and rear oil galley plugs.
(14) Remove the connecting rods and the pistons.
Remove the connecting rod and piston assemblies
through the top of the cylinder bores.
(15) Remove the crankshaft.
CLEANING
Thoroughly clean the oil pan and engine block gas
ket surfaces.
Use compressed air to clean out:
• The galley at the oil filter adaptor hole, the filter
CRANKSHAFT CRANKSHAFT bypass hole (Fig. 8).
OIL SEAL
FILTER BYPASS
HOLE
J8909-149
Fig. 7 Replacement of Rear Crankshaft Oil Seal

INSTALLATION
(1) Coat the outer lip of the replacement rear main
bearing seal with engine oil.
(2) Carefully position the seal into place. Use rear
main Seal Installer Tool 6271 to install the seal flush
with the cylinder block.
CAUTION: T h e felt lip must be located inside the

flywheel mounting surface. If the lip i s not posi
tioned correctly the flywheel could tear the seal. OIL FILTER
ADAPTOR HOLE J9009-50
(3) Install the flywheel or converter drive plate. Fig. 8 Oil Filter Adaptor Hole
New bolts MUST be used when installing the fly
wheel or converter plate. Tighten the new bolts to 68 • The front and rear oil galley holes (Figs. 9 and 10).
N-m (50 ft. lbs.) torque. Turn the bolts an additional • The feed holes for the crankshaft main bearings.
60°. Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
CYLINDER B L O C I threads of the front and rear oil galley plugs.
Remove the Engine Assembly from the vehicle. Tighten the plugs to 41 N-m (30 ft. lbs.) torque.
DISASSEMBLY INSPECTION-CYLINDER BORE

Refer to the applicable sections for detailed instruc (1) Use a bore gauge to measure each cylinder bore
tions. diameter (Fig. 11). If a bore gauge is not available,
(1) Drain the engine oil. Remove and discard the use an inside micrometer.
oil filter.
J 2 J L ENGINE 9 - 45
J8909-134
Fig. 11 Cylinder Bore Measurement

HONING—CYLINDER BORE
The honing operation should be closely coordinated
with the fitting of pistons and rings. This will ensure
specified clearances are maintained.
Refer to Standard Service Procedures in the begin
ning of this Group for the proper honing of cylinder
bores.
ASSEMBLY
HOLE
Refer to the applicable sections for detailed instruc
Fig. 10 Rear Oil Galley Hole tions.
(1) Install the crankshaft.
(2) Measure the cylinder bore diameter crosswise
(2) Install the connecting rods and the pistons
to the cylinder block near the top of the bore. Repeat
the measurement near the bottom of the bore. (3) Install the front and rear oil galley plugs.
(3) Determine taper by subtracting the smaller di (4) Install the timing chain tensioner.
ameter from the larger diameter. (5) Install the camshaft.
(4) Rotate measuring device 120° and repeat steps (6) Install the sprockets and chain as an assembly.
above. Finally, rotate the device another 120° and re (7) Install the oil slinger to the crankshaft.
peat measurements. (8) Install the timing chain bumper.
(5) Determine out-of-roundness by comparing the (9) Install the timing case cover seal.
difference between each 120° measurement. (10) Install the timing case cover.
(6) If cylinder bore taper does not exceed 0.025 mm (11) Install the oil pan gasket and oil pan.
(0.001 inch) and out-of-roundness does not exceed (12) Install the vibration damper.
0.025 mm (0.001 inch), the cylinder bore can be (13) Install the water pump. Tighten the mounting
honed. If the cylinder bore taper or out-of-round con bolts to 34 N*m (25 ft. lbs.) torque.
dition exceeds these maximum limits, the cylinder (14) Remove the distributor from the cylinder
must be bored and then honed to accept an oversize block.
piston. A slight amount of taper always exists in the (15) Lubricate the oil filter seal with clean engine
cylinder bore after the engine has been in use for a oil. Tighten oil filter to 18 N*m (13 ft. lbs.) torque.
period of time. (16) Install the engine into the vehicle.
(17) Fill the engine with clean lubrication oil (re
fer to Group 0, Lubrication and Maintenance).
(18) Fill the cooling system (refer to Group 7, Cool
ing System for the proper procedures).
SPECIFICATIONS ENGINE SPECIFICATIONS
Camshaft Cylinder Block
Hydraulic Tappet Clearance . Z e r o Lash Deck Height 2 3 6 . 7 3 mm

Bearing Clearance. 0 . 0 2 5 - 0 . 0 7 6 mm ( 9 . 3 2 0 in)
( 0 . 0 0 1 - 0 . 0 0 3 in) Deck Clearance 0 . 0 0 0 mm
Bearing Journal Diameter ( 0 . 0 0 0 in)
No.l . . . . . . . . . . 5 1 . 5 4 - 5 1 . 5 6 mm Cylinder Bore Diameter
( 2 . 0 2 9 - 2 . 0 3 0 in) Standard 9 8 . 4 2 - 9 8 . 4 8 mm
No.2 . . . . . . . . . . . . 5 1 . 2 8 - 5 1 . 3 1 mm ( 3 . 8 7 5 1 - 3 . 8 7 7 5 in)
( 2 . 0 1 9 - 2 . 0 2 0 in) Taper (Max.) . . . . 0 . 0 2 5 mm
No.3............. . . . 5 1 . 0 3 - 5 1 . 0 5 mm ( 0 . 0 0 1 in)
( 2 . 0 0 9 - 2 . 0 1 0 in) Out-of-Round (Max.) . . . . 0 . 0 2 5 mm
No.4.................... . . . . . 5 0 . 7 8 - 5 0 . 8 0 mm ( 0 . 0 0 1 in)
( 1 . 9 9 9 - 2 . 0 0 0 in) Tappet Bore Diameter 2 3 . 0 0 0 - 2 3 . 0 2 5 mm
Base Circle Runout 0 . 0 3 mm - max. ( 0 . 9 0 5 5 - 0 . 9 0 6 5 in)
( 0 . 0 0 1 in - max.) Flatness . . . . 0 . 0 3 mm per 2 5 mm
Camshaft Lobe Lift 6 . 7 3 1 mm ( 0 . 0 0 1 in per 1 in)
( 0 . 2 6 5 in) 0 . 0 5 mm per 1 5 2 mm
Valve Lift 1 0 . 7 7 mm ( 0 . 0 0 2 in per 6 in)
( 0 . 4 2 4 in) 0 . 2 0 mm - max. for total length
Intake Valve Timing ( 0 . 0 0 8 in - max. for total length)
Opens 16°BTDC M a i n Bearing Bore Dia 6 8 . 3 5 1 4 - 6 8 . 3 7 6 8 mm
Closes .74°ABDC ( 2 . 6 9 1 - 2 . 6 9 2 in)
Exhaust Valve T i m i n g
Opens 60°BBDC Connecting Rods
Closes 30°ATDC
Valve Overlap 46° Total W e i g h t (Less Bearing) 6 5 7 - 6 6 5 grams
Intake Duration 270° ( 2 3 . 1 7 - 2 3 . 4 5 oz)
Exhaust Duration .270° Length (Center-to-Center) 1 5 5 . 5 2 - 1 5 5 . 6 2 mm
( 6 . 1 2 3 - 6 . 1 2 7 in)
Crankshaft Piston Pin Bore Diameter 2 3 . 5 9 - 2 3 . 6 2 mm
( 0 . 9 2 8 8 - 0 . 9 2 9 8 in)
End Play . . . 0 . 0 3 8 - 0 . 1 6 5 mm Bore (Less Bearings) 5 6 . 0 8 - 5 6 . 0 9 mm
( 0 . 0 0 1 5 - 0 . 0 0 6 5 in) ( 2 . 2 0 8 0 - 2 . 2 0 8 5 in)
M a i n Bearing Journal D i a 6 3 . 4 8 9 - 6 3 . 5 0 2 mm Bearing Clearance 0 . 0 2 5 - 0 . 0 7 6 mm
( 2 . 4 9 9 6 - 2 . 5 0 0 1 in) Preferred 0 . 0 4 4 - 0 . 0 5 0 mm
M a i n Bearing Journal W i d t h ( 0 . 0 0 1 - 0 . 0 0 3 in)
No.l . . . 2 7 . 5 8 - 2 7 . 8 9 mm Preferred . . ( 0 . 0 0 1 5 - 0 . 0 0 2 0 in)
( 1 . 0 8 6 - 1 . 0 9 8 in) Side Clearance. . . . 0 . 2 5 - 0 . 4 8 mm
No.2... 3 2 . 2 8 - 3 2 . 3 3 mm ( 0 . 0 1 0 - 0 . 0 1 9 in)
( 1 . 2 7 1 - 1 . 2 7 3 in) T w i s t (Max.) 0 . 0 0 1 mm per mm
No.34-5 . . 3 0 . 0 2 - 3 0 . 1 8 mm ( 0 . 0 0 1 in per in)
( 1 . 1 8 2 - 1 . 1 8 8 in) Bend (Max.) 0 . 0 0 1 mm per mm
M a i n Bearing Clearance 0 . 0 3 - 0 . 0 6 mm ( 0 . 0 0 1 in per in)
Preferred 0 . 0 5 1 mm
( 0 . 0 0 1 - 0 . 0 0 2 5 in) Cylinder Compression Pressure
Preferred ( 0 . 0 0 2 in)
Connecting Rod Journal Dia 5 3 . 1 7 - 5 3 . 2 3 mm Ratio. ..................9.2:1
( 2 . 0 9 3 4 - 2 . 0 9 5 5 in) Pressure Range.... . . 8 2 7 - 1 0 3 4 kPa
Connecting Rod Journal W i d t h 2 7 . 1 8 - 2 7 . 3 3 mm ( 1 2 0 - 1 5 0 psi)
(1.070-'1.076 in) M a x . Variation Between Cylinders 2 0 6 kPa
Out-of-Round (Max. All Journals) 0 . 0 1 3 mm ( 3 0 psi)
( 0 . 0 0 0 5 in)
T a p e r (Max. - All Journals) 0 . 0 1 3 mm
( 0 . 0 0 0 5 in)
J9209-21
ENGINE SPECIFICATIONS (CONT.)
Cylinder Head Valve Springs
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9 . 9 - 5 2 . 9 cc Free Length (Approx.) 4 9 . 9 6 2 mm

( 3 . 0 4 - 3 . 2 3 cu. in.) ( 1 . 9 6 7 in)
Valve Guide I D . (Integral) . 7 . 9 5 - 7 . 9 7 mm Spring Tension
( 0 . 3 1 3 - 0 . 3 1 4 in) Valve Closed 3 5 5 - 4 0 0 N @ 4 1 . 6 5 6 mm
Valve Stem-to-Guide Clearance 0 . 0 2 5 - 0 . 0 7 6 mm ( 8 0 - 9 0 l b f @ 1 . 6 4 0 in)
( 0 . 0 0 1 - 0 . 0 0 3 in) Valve Open 8 9 0 N @ 3 0 . 8 8 6 mm
Intake Valve Seat Angle ...44.5° ( 2 0 0 l b f @ 1 . 2 1 6 in)
Exhaust Valve Seat Angle 44.5° Inside Diameter . . 2 4 . 0 8 - 2 4 . 5 9 mm
Valve Seat W i d t h 1 . 0 2 - 1 . 5 2 mm ( 0 . 9 4 8 - 0 . 9 6 8 in)
( 0 . 0 4 0 - 0 . 0 6 0 in)
Valve Seat Runout 0 . 0 6 4 mm Pistons
( 0 . 0 0 2 5 in)
Flatness 0 . 0 3 mm per 2 5 mm W e i g h t (Less Pin) . . . . 5 6 3 - 5 6 7 grams
( 0 . 0 0 1 in per 1 in) (19.86-20.00 oz)
0 . 0 5 mm per 1 5 2 mm Piston Pin Bore (Centerline-to-Piston Top) 4 0 . 6 1 - 4 0 . 7 2 mm
( 0 . 0 0 2 in per 6 in) ( 1 . 5 9 9 - 1 . 6 0 3 in)
0 . 2 0 mm - max. for total length Piston-to-Bore Clearance 0 . 0 3 3 - 0 . 0 5 3 mm
( 0 . 0 0 8 in - max. for total length) Preferred. 0 . 0 3 3 - 0 . 0 3 8 mm
( 0 . 0 0 1 3 - 0 . 0 0 2 1 in)
Rocker Arms, Push Rods & Tappets Preferred ( 0 . 0 0 1 3 - 0 . 0 0 1 5 in)
Piston Ring G a p Clearance
RockeV A r m Ratio .1.6:1 Compression Rings 0 . 2 5 - 0 . 5 1 mm
Push Rod Length 2 4 1 . 3 0 0 - 2 4 1 . 8 0 8 mm ( 0 . 0 1 0 - 0 . 0 2 0 in)
( 9 . 5 0 0 - 9 . 5 2 0 in) O i l Control Steel Rails 0 . 3 8 1 - 1 . 3 9 7 mm
Push Rod Diameter 7 . 9 2 - 8 . 0 0 mm ( 0 . 0 1 5 - 0 . 0 5 5 in)
( 0 . 3 1 2 - 0 . 3 1 5 in) Piston Ring Side Clearance
Hydraulic Tappet Diameter 2 2 . 9 6 2 - 2 2 . 9 7 4 mm Compression Rings 0 . 0 2 5 - 0 . 0 8 1 mm
( 0 . 9 0 4 - 0 . 9 0 4 5 in) Preferred 0 . 0 2 5 mm
Tappet-to-Bore Clearance 0 . 0 2 5 - 0 . 0 6 3 mm ( 0 . 0 0 1 - 0 . 0 0 3 2 in)
( 0 . 0 0 1 - 0 . 0 0 2 5 in) Preferred ( 0 . 0 0 1 in)
O i l Control Ring . . . 0 . 0 2 5 - 0 . 2 1 6 mm
Valves Preferred 0 . 0 8 mm
( 0 . 0 0 1 - 0 . 0 0 8 5 in)
Length (Tip - to - Gauge Dimension Line) Preferred ( 0 . 0 0 3 in)
Intake 1 2 4 . 4 3 5 - 1 2 5 . 0 7 0 mm Piston Ring Groove Height
( 4 . 8 9 9 - 4 . 9 2 4 in) Compression Rings 2 . 0 1 9 - 2 . 0 4 5 mm
Exhaust............ . . . . . . . . . . 1 2 5 . 1 2 0 - 1 2 5 . 7 5 5 mm ( 0 . 0 7 9 5 - 0 . 0 8 0 5 in)
( 4 . 9 2 7 - 4 . 9 5 2 in) O i l Control Ring 4 . 7 8 - 4 . 8 0 mm
Valve Stem Diameter 7 . 8 9 9 - 7 . 9 2 5 mm ( 0 . 1 8 8 0 - 0 . 1 8 9 5 in)
( 0 . 3 1 1 - 0 . 3 1 2 in) Piston Rinp Groove Diameter
Stem-to-Guide Clearance 0 . 0 2 5 - 0 . 0 7 6 mm Compression Rings 8 7 . 7 8 - 8 7 . 9 0 mm
( 0 . 0 0 1 - 0 . 0 0 3 in) ( 3 . 4 5 6 - 3 . 4 6 1 in)
Valve Head Diameter O i l Control Ring . 8 7 . 5 0 - 8 7 . 7 5 mm
Intake.. 4 8 . 3 8 7 - 4 8 . 6 4 1 mm ( 3 . 4 4 5 - 3 . 4 5 5 in)
( 1 . 9 0 5 - 1 . 9 1 5 in) Piston Pin Bore Diameter 23.647 - 23.655 mm
Exhaust 3 7 . 9 7 3 - 3 8 . 2 2 7 mm ( 0 . 9 3 1 0 - 0 . 9 3 1 3 in)
( 1 . 4 9 5 - 1 . 5 0 5 in) Piston Pin Diameter 23.637 - 23.640 mm
Valve Face Angle (0.9306 - 0.9307 in)
Intake 45° Piston-to-Pin Clearance 0.0076 - 0.0178 mm
Exhaust 45° Preferred . . . . 0.015 m m - Loose
T i p Refinishing (Max. Allowable) . 0 . 2 5 mm (0.0003 - 0.0007 in)
( 0 . 0 1 0 in) Preferred.. ( 0 . 0 0 0 6 in - Loose)
Piston-to-Pin Connecting Rod (Press F i t ) . . . 8.9 kN
i ( 2 0 0 0 lb f)
J§20f-S1
9 - 48 2.5L ENGINE
ENGINE SPECIFICATIONS (CONT.)
Oil Pump Oil Pressure
Gear-to-Body Clearance (Radial) 0.051 -0.102 mm Min. Pressure (600 rpm) 89.6 kPa
Preferred 0.051 mm (13 psi)
(0.002-0.004 in) At Idle Speed (800 rpm)... 172 - 241 kPa
Preferred (0.002 in) (25 - 35 psi)
Gear End Clearance At 1600 rpm & higher 255 - 517 kPa
Plastigage 0.051 -0.152 mm (37-75 psi)
Preferred 0.051 mm Oil Pressure Relief .517 kPa
(0.002 -0.006 in) (75 psi)
Preferred (0.002 in)
Feeler Gauge 0.1016-0.2032 mm
Preferred 0.1778 mm
(0.004-0.008 in)
Preferred.. (0.007 in) J9209-23
A/C Compressor Bracket-to- Generator Mounting Bracket-

Engine Bolts 34 N-m (25 ft. lbs.) to-Engine Bolts 38 N-m (28 ft. lbs.)
A/C Compressor Mounting Generator Mounting-to-
Bolts 27 N m (20 ft. lbs.) Head Bolts 45 N m (33 ft. lbs.
A/C Low Pressure Service Main Bearing Bolts 108 N-m (80 ft. lbs.
Valve Nut 38 N m (28 ft. lbs.) Oil Filter 18 N-m (13 ft. lbs.
Block Heater Nut 1.8 N m (16 in. lbs.) 41 N-m (30 ft. lbs.
Oil Galley Plug
Camshaft Sprocket Bolt 108 N m (80 ft. lbs.) 13 N-m (114 in. lbs.
Oil Pan Bolts (1/4-20)
Connecting Rod Nuts 45 N m (33 ft. lbs.) 18 N-m (156 in. lbs.
Converter Plate Bolts 68 N m (50 ft. lbs.) (5/16-18)
Oil Pan Drain Plug 41 N-m (30 ft. lbs.
+60° (+60°)
Crossmember-to-Sill Bolts Oil Pump Attaching Bolts
(XJ Vehicles) 41 N-m (30 ft. lbs.) (Short Bolts) .' 14 N-m (10 ft. lbs.)
Cylinder Head Bolts (Long Bolts) 23 N-m (17 ft. lbs.)
(#1-6 &#8-10) 149 N-m (110 ft. lbs.) 8 N-m (70 in. lbs.)
Oil Pan Cover Bolts
(#7) 135 N-m (100ft. lbs.) Power Steering Pump Pressure
Cylinder Head Cover Bolts . . . 9 N-m (75 in. lbs.) 52 N-m (38 ft. lbs.)
Hose Nut
Driver Plate-to-Torque Rear Support Bracket-to-
Converter Bolts 54 N m (40 ft. lbs.) Transmission Bolts (YJ) 56 N-m (41 ft. lbs.)
Engine Shock Damper Rear Support Bracket Stud Nuts
Stud Nuts 23 N-m (17ft. lbs.) (XJ-Manual Trans.) 46 N-m (34ft. lbs.)
Engine Support Bracket Bolts . 61 N m (45 ft. lbs.) Rear Support Bracket Stud Nuts
Exhaust Manifold-to-Pipe Nuts 27 N-m (20ft. lbs.) (XJ-Automatic Trans.) 75 N-m (55 ft. lbs.)
Flywheel/Converter Housing Rocker Arm Assembly-to-
38 N-m (28 ft. lbs.) Cylinder Head Capscrews . . . 28 N-m (21 ft. lbs.)
Bolts .
7 N-m (60 in. lbs.) Skid Plate-to-Sill Bolts (YJ) 88 N-m (65 ft. lbs.)
Front Cover-to-Block Bolts . . . .
Spark Plugs 37 N-m (27 ft. lbs.)
Front Support Bracket-to-
61 N-m (45 ft. lbs.) Starting Motor Mounting
Cylinder Block Bolts 45 N-m (33 ft. lbs.)
Bolts
Front Support Cushion-to- 65 N m (48 ft. lbs.) Timing Case Cover-to-
Mount Thru Bolt 7 N-m (60 in. lbs.)
Block Bolts
Front Support Cushion-to-
41 N-m 30 ft. lbs.) Transmission Support Cushion
Sil'l Bracket (XJ) Nuts(YJ) 56 N-m (41 ft. lbs.)
(YJ) . . . 65 N m 48 ft. lbs.)
Trans. Support Cushion/Torque
Fuel Pump Bolts 22 N-m 16 fl. lbs.) 56 N-m (41 ft. lbs.)
Arm Bracket Bolts (YJ)
Generator Adjusting Bolt . . . . 24 N-m (18 ft. lbs.) Vibration Damper Bolts 108 N-m (80 ft. lbs.)
Generator Pivot Bolt/Nut 38 N-m (28 ft. lbs.)
Water Pump-to-Block Bolts 34 N-m (25 ft. lbs.)
J9309-92
4 J L ENGINE 9 - 49
4.0L ENGINE SERVICE PROCEDURES
INDEX
page page
Camshaft 68 Oil Pan . .... . 71
Camshaft Pin Replacement . 69 Oil Pump . 72
Crankshaft Main Bearings 80 Pistons and Connecting Rods 74
Cylinder Block 85 Rear Main Oil Seals . . . . . . . . . . . . . . . . . . . . . . 84
Engine Assembly—XJ Vehicles . 53 Rocker Arms 58
Engine Assembly—YJ Vehicles 55 Specifications . 87
Engine Cylinder Head 58 Timing Case Cover 66
Engine Cylinder Head Cover . 57 Timing Case Cover Oil Seal Replacement . . . . . . 66
Engine Mount—Rear (XJ Vehicles) . 51 Timing Chain and Sprockets 67
Engine Mount—Rear (YJ Vehicles) 52 Valve Springs and Oil Seals 60
Engine Mounts—Front 50 Valve Timing 65
General Information 49 Valves and Valve Springs 61
Hydraulic Tappets 63 Vibration Damper 65
GENERAL INFORMATION
The 4.0 Liter (242 CID) six-cylinder engine is an
In-line, lightweight, overhead valve engine (Fig. 1).
Engine Type In-line 6 Cylinder

Bore and Stroke 9 8 . 4 x 8 7 . 4 m m ( 3 . 8 8 x 3 . 4 4 in.)
Displacement 4 . 0 L (242 cu. in.)
Compression Ratio 8.8:1
Torque
(XJ Vehicles) 3 0 5 N m (225 ft. lbs.) @ 4 0 0 0 rpm
(YJ Vehicles) . 2 9 8 N m (220 ft. lbs.) @ 4 0 0 0 rpm
Firing Order l_5_3_6-2-4
Lubrication Pressure Feed—Full Flow Filtration
Engine O i l Capacity . . . 5 . 7 L (6 Quarts)
Cooling System Liquid Cooled—Forced Circulation
Cooling System Capacity
(XJ Vehicles) 11.4L (12 Quarts)
(YJ Vehicles) 9 . 9 L (10.5 Quarts)
Cylinder Block Cast Iron
Fig. 2 Engine Firing Order
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron BUILD DATE CODE
Camshaft Cast Iron The engine Build Date Code is located on a ma
Pistons Aluminum Alloy (with Struts)
chined surface on the right side of the cylinder block
Pistons Combustion
Cavity Double Quench between the No.2 and No.3 cylinders (Fig. 3).
Connecting Rods Cast Iron The digits of the code identify:
(1) 1st Digit-The year (3 = 1993).
J9309-51
(2) 2nd & 3rd Digits-The month (01 - 12).
Fig. 1 Engine Description (3) 4th & 5th Digits—The engine type/fuel system/
compression ratio (MX = A 4.0 Liter (242 CID) 8.8:1
This engine is designed for unleaded fuel. compression ratio engine with a multi-point fuel in
The engine cylinder head has dual quench-type jection system).
combustion chambers that create turbulence and fast (4) 6th & 7th Digits-The day of engine build (01 -
burning of the air/fuel mixture. This results in good 31).
fuel economy. FOR EXAMPLE: Code * 301MX12 * identifies a
The cylinders are numbered 1 through 6 from front 4.0 liter (242 CID) engine with a multi-point fuel in
to rear. The firing order is 1-5-3-6-2-4 (Fig. 2). jection system, 8.8:1 compression ratio and built on
The crankshaft rotation is clockwise, when viewed January 12, 1993.
from the front of the engine. The crankshaft rotates
within seven main bearings. The camshaft rotates
within four bearings.
9 - SO 4 J L ENGINE
J9209-54
Fig. 3 Build Date Code Location

OVERSIZE AND UNDERSIZE COMPONENT DISTRIBUTOR
CODES
IGNITION
Some engines may be built with oversize or under BOSS J9209-10
COIL
size components such as:
• Oversize cylinder bores. Fig. 5 Oversize and Undersize Component Code
• Oversize camshaft bearing bores. Location
• Undersize crankshaft main bearing journals.
• Undersize connecting rod journals. ENGINE MOUNTS—FRONT
These engines are identified by a letter code (Fig. Resilient rubber cushions support the engine at
4) stamped on a boss between the ignition coil and each side of the engine (Figs. 6 and 7).
the distributor (Fig. 5).
REMOVAL
mm COMPONENT UNDERSIZE (2) Raise the vehicle.
(3) Support the engine.
p One or more 0.254 mm (4) Remove the nut from the through bolt (Figs. 6
connecting rod (0.010 in) and 7). Do not remove the through bolt.
bearing journals (5) Remove the retaining bolts/nuts from the en
M All crankshaft 0.254 mm gine support cushions (Figs. 6 and 7).
main bearing (0.010 in) (6) Remove the through bolt.
journals (7) Remove the engine support cushions.
PM All crankshaft 0.254 mm
main bearing (0.010 in) INSTALLATION
journals and (1) If the engine support bracket was removed, po
one or more sition the bracket and install the attaching bolts
connecting rod
journals (Figs. 7 and 8). Tighten the bolts to 61 N-m (45 ft.
lbs.) torque.
(2) Place the engine support cushion into position
com COMPONENT OVEiSiZE
(Figs. 6 and 7).
(3) Install the through bolt and the retaining nut
(Figs. 6 and 7).
B All cylinder 0.254 mm
bores (0.010 in)
(4) Install the engine support cushion retaining
bolt and nut. Tighten the XJ vehicle retaining bolts/
C All camshaft 0.254 mm nuts to 40 N-m (30 ft. lbs.) torque. Tighten the YJ
bearing bores (0.010 in) vehicle retaining bolts/nuts to 65 N-m (48 ft. lbs.)
torque.
(5) Tighten the through bolt nut to 65 N-m (48 ft.
J8909-54 lbs.) torque.
(6) Remove the engine support.
Fig. 4 Oversize and Undersize Component Codes (7) Lower the vehicle.
J 4 J L ENGINE S - 51
ENGINE MOUNT-REAR (XJ VEHICLES)

A resilient rubber cushion supports the transmis
housing and the rear support crossmember or skid
plate.
REMOVAL
port cushion to the crossmember (Figs. 8 and 9).
(4) Remove the crossmember.
(5) Remove the transmission support cushion.
(6) If necessary, remove the bolts holding the rear
support bracket to the transmission (Figs. 8 and 9).
Remove the rear support adaptor bracket on 2WD ve
hicles with automatic transmission. Remove the
bracket and adaptor.
Fig. 6 Front Mounts—XJ Vehicles
J9109-174
Fig. 8 Rear Mount—XJ Vehicles (Automatic

Transmission)
INSTALLATION
(1) If removed, position the rear support bracket to
the transmission and install the bolts. On 2WD vehi
cles with automatic transmissions, position the adap
tor and support bracket and install the bolts.
Fig. 7 Front Mounts—YJ Vehicles Vehicles with automatic transmissions, tighten the
TRANSMISSION (7) Remove the transmission support cushion and

transmission support bracket.
(8) Separate the transmission support cushion from
the transmission support bracket.
ASSEMBLY J9109-175
Fig. 9 Rear Mount—XJ Vehicles (Manual

Transmission)
bolts to 75 N-m (55 ft. lbs.) torque. Vehicles with
manual transmissions, tighten the bolts to 46 N-m
(2) Position the transmission support cushion and
crossmember to the studs of the rear support bracket.
Install the crossmember-to-sill bolts and tighten to
41 N-m (30 ft. lbs.) torque. J9109-173
(3) Remove the transmission support.
(4) Install the rear support bracket nuts to the Fig. 10 Rear Mount— YJ Vehicles (Automatic
studs and tighten to 46 N-m (34 ft. lbs) torque. Transmission)
(5) Lower the vehicle. INSTALLATION
(6) Connect negative cable to battery. (1) Position the transmission support bracket and
transmission support cushion to the transmission and
ENGINE MOUNT-REAR (YJ VEHICLES) install the bolts (Figs. 10 and 11). Tighten the bolts
A resilient rubber cushion supports the transmis to 56 N-m (41 ft. lbs.) torque.
(2) MANUAL TRANSMISSION - Position the in
housing and the rear support crossmember or skid sulator stud assembly and upper nut (Fig. 11).
plate. Tighten the nut to 40 N-m (360 in. lbs.) torque.
REMOVAL (3) Position the skid plate to the studs of the trans
(1) Disconnect negative cable from battery. mission support cushion and the insulator stud (man
(2) Raise the vehicle and support the transmission. ual transmission) - (Figs. 11 and 12). Install the skid
(3) Remove the nuts holding the transmission sup plate bolts to the sill and tighten to 88 N-m (65 ft.
port cushion and the insulator stud nut (manual lbs.) torque. Tighten the lower insulator stud nut to
transmission) to the skid plate (Figs. 11 and 12). 40 N-m (360 in. lbs.) torque.
(4) M A N U A L TRANSMISSIONS - Remove the (4) Remove the transmission support.
upper nut from the insulator stud. (5) Install the transmission support cushion nuts
(5) Remove the skid plate bolts and th^ skid plate and tighten to 56 N-m (41 ft. lbs) torque.
(Figs. 10 and 11). Remove the insulator stud assem (6) Lower the vehicle.
bly (manual transmissions) — (Fig. 11).
(6) Remove the bolts holding the transmission sup
port cushion and transmission support bracket to the
transmission (Figs. 10 and 11).
(7) Remove the fan shroud (Fig. 12) and electric
cooling fan.
(8) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(9) Disconnect radiator fan switch wire connector.
(10) Vehicles with Air Conditioning:
(a) Discharge the A/C condenser.
(b) Remove the service valves and cap the com
pressor ports.
(11) Remove the radiator or radiator/condenser (if
equipped with A/C).
(12) Remove the fan assembly from the idler pul
ley.
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump (Fig. 12).
SKID
J9109-172 PLATE
Fig. 11 Rear Mount—YJ Vehicles (Manual COOLANT n FAN

RECOVERY oJj@@ro SHROUDS
Transmission) HOSE = = = = = =
ENGINE ASSEMBLY—XJ VEHICLES Hose, Fan Shroud & Heater hoses
(14) Disconnect the throttle linkages (Fig. 13).
REMOVAL (15) Disconnect the speed control cable (if
(1) Disconnect the battery cables. Remove the bat equipped)—(Fig. 13).
tery. (16) Disconnect the line pressure cable (if equipped
(2) Mark the hinge locations on the hood panel for with automatic transmission).
alignment reference during installation. Remove the (17) Disconnect injection system wire harness con
engine compartment lamp. Remove the hood. nector at the dash panel.
(18) Disconnect the distributor electrical connec
WARNING: T H E COOLANT IN A R E C E N T L Y O P E R tion and the oil pressure switch connector.
A T E D ENGINE I S H O T AND P R E S S U R I Z E D . U S E (19) Disconnect the quick-connect fuel lines at the
C A R E T O P R E V E N T SCALDING B Y H O T COOLANT, fuel rail and return line by squeezing the two retain
CAREFULLY RELEASE T H E P R E S S U R E BEFORE ing tabs against the fuel tube (Fig. 13). Pull the fuel
REMOVING T H E R A D I A T O R DRAIN COCK AND tube and retainer from the quick-connect fitting (re
CAP. fer to Group 14, Fuel System for the proper proce
dure).
(3) Remove the radiator drain cock and radiator (20) Remove the fuel line bracket from the intake
cap to drain the coolant. Do not waste usable coolant. manifold.
If the solution is clean, drain the coolant into a clean (21) Remove the air cleaner assembly (Fig. 14).
container for reuse. (22) Remove the power brake vacuum check valve
(4) Remove the lower radiator hose. from the booster, if equipped.
(5) Remove the upper radiator hose and coolant re (23) If equipped with power steering (Fig. 14):
covery hose (Fig. 12). (a) Disconnect the hoses from the fittings at the
(6) Remove upper radiator support retaining bolts steering gear.
and remove radiator support. (b) Drain the pump reservoir.
9 - 54 4.QL ENGINE J
ACCELERATOR — S P E E D CONTROL (30) Remove the exhaust pipe support.
(31) Remove the flywheel/converter housing access
cover.
(32) Vehicles with Automatic Transmission:
(a) Mark the converter and drive plate location.
(b) Remove the converter-to-drive plate bolts.
(33) Remove the upper flywheel/converter housing
bolts and loosen the bottom bolts.
(34) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(36) Attach a lifting device to the engine.
(37) Raise the engine off the front supports.
(38) Place a support or floor jack under the con
verter (or flywheel) housing.
(39) Remove the remaining converter (or flywheel)
housing bolts.
(40) Lift the engine out of the engine compart
ment.
INSTALLATION
Fig. 13 Accelerator Cable, Speed Control Cable,
CAUTION: When installing the engine into a vehicle
Automatic Transmission Control Cable & Quick-
equipped with an automatic transmission, be care
Connect Fuel Lines
ful not to damage the trigger wheel on the flywheel.
(c) Cap the fittings on the hoses and steering (1) Attach a lifting device to the engine and lower
gear to prevent foreign objects from entering the the engine into the engine compartment. For easier
system. installation, it may be necessary to remove the en
gine mount cushions from the engine mount bracket
as an aide in alignment of the engine to the trans
mission.
(2) Vehicles with Manual Transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.
(c) Install and tighten the flywheel housing
lower bolts finger tight.
(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger tight.
Fig. 14 Air Cleaner Assembly & Power Steering (4) Install the engine mount cushions (if removed).
Pump (5) Lower the engine and engine mount cushions
(24) Identify, tag and disconnect all necessary wire onto the engine compartment brackets. Install the
connectors and vacuum hoses. bolts and finger tighten the nuts.
(25) Raise and support the vehicle. (6) Remove the engine lifting device.
(26) Disconnect the wires from the starter motor (7) Raise and support the vehicle.
(8) Install the remaining flywheel/converter hous
solenoid.
ing bolts. Tighten all bolts to 38 N»m (28 ft. lbs.)
(27) Remove the starter motor. »
torque.
(28) Disconnect the exhaust pipe from the mani
fold.
(a) Install the converter-to-drive plate bolts.
(29) Disconnect the engine speed sensor wire con (b) Ensure the installation reference marks are
nection. aligned.
(10) Install the flywheel/converter housing access (40) Align the hood to the scribe marks. Install the
cover. hood.
(11) Install the exhaust pipe support and tighten (41) Connect the vacuum harness connector.
the screw. (a) Firmly push the connectors together ensuring
(12) Tighten the engine mount-to-bracket bolts. that the retaining tabs are engaged.
(13) Connect the engine speed sensor wire connec (b) Insert the vacuum connector assembly into
tions and tighten the screws. the retaining bracket on the intake manifold.
(14) Connect the exhaust pipe to the manifold. (42) Install the air cleaner assembly.
(15) Install the starter motor and connect the ca (43) Install the battery and connect the battery ca
ble. ble,
(16) Connect the wires to the starter motor sole
noid.
R E C T L I N E W I T H T H E F A N . DO NOT P U T Y O U R
(18) Connect all the vacuum hoses and wire con HANDS N E A R T H E P U L L E Y S , B E L T S O R F A N . DO
nectors identified during engine removal. NOT W E A R L O O S E CLOTHING.
(19) If equipped with power steering:
(a) Remove the protective caps (44) Start the engine, inspect for leaks and correct
(b) Connect the hoses to the fittings at the steer the fluid levels, as necessary.
ing gear. Tighten the nut to 52 N*m (38 ft. lbs.)
torque. ENGINE ASSEMBLY-YJ VEHICLES
(c) Fill the pump reservoir with fluid.
(20) Install the power brake vacuum check valve REMOVAL
to the booster, if equipped. (1) Place a protective cloth over the windshield
(21) Connect the fuel inlet and return hoses at the frame. Raise the hood and rest it on the windshield
fuel rail. Verify that the quick-connect fitting assem frame (Fig. 15).
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(22) Install the fuel line bracket to the intake
manifold.
(23) Connect the distributor electrical connector
and oil pressure switch connector.
(24) Connect the injection system wire harness
connector on the dash panel.
(25) Connect the line pressure cable (if equipped
with automatic transmission).
(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/condenser (if
equipped with A/C).
(31) Connect the service valves to the A/C com
pressor ports, if equipped with A/C.
(32) Charge the air conditioner system.
(33) Connect radiator fan switch wire.
(34) Connect the radiator hoses and automatic
Fig. 15 Hood on Windshield Frame
transmission fluid cooler pipes, if equipped.
(35) Install the fan shroud, electric cooling fan and (2) Disconnect the battery cables. Remove the bat
radiator/condenser (if equipped with A/C). tery.
(36) Install upper radiator support.
(37) Connect the upper radiator hose and tighten WARNING: T H E COOLANT IN A R E C E N T L Y O P E R
the clamp. A T E D ENGINE I S H O T AND P R E S S U R I Z E D . U S E
(38) Connect the lower radiator hose and tighten C A R E T O P R E V E N T SCALDING B Y H O T COOLANT.
the clamp. CAREFULLY RELEASE T H E PRESSURE BEFORE
(39) Fill the cooling system with reusable coolant REMOVING T H E R A D I A T O R DRAIN COCK AND
and/or new coolant. CAP.
S - 56 4 J L ENGINE J
(3) Remove the radiator drain cock and radiator (21) Remove the fan shroud screws.
cap to drain the coolant. Do not waste reusable cool (22) Remove the radiator attaching bolts.
ant. If the solution is clean, drain the coolant into a (23) Remove the radiator and fan shroud (Fig. 17).
clean container for reuse. Refer to Group 7, Cooling System for the proper pro
(4) Disconnect the wire connectors from the gener cedure.
ator. (24) Remove the fan and spacer or Tempatrol fan
(5) Disconnect the ignition coil and distributor assembly.
wire connectors. (25) Install a 5/16 X 1/2-inch SAE capscrew
(6) Disconnect the oil pressure sender wire connec through fan pulley into water pump flange. This will
tor. maintain the pulley and water pump in alignment
(7) Disconnect the wires at the starter motor sole when crankshaft is rotated.
noid and injection wire harness connector. (26) Remove the power brake vacuum check valve
(8) Disconnect the quick-connect fuel lines at the from the booster, if equipped.
fuel rail and return line by squeezing the retaining
(27) If equipped with power steering (Fig. 17):
tabs against the fuel tube (Fig. 16). Pull the fuel
(a) Disconnect the hoses from the fittings at the
tube and retainer from the quick-connect fitting (re
steering gear.
fer to Group 14, Fuel System for the proper proce
(b) Drain the pump reservoir.
dure).
(9) Remove the fuel line bracket from the intake (c) Cap the fittings on the hoses and steering
manifold. gear to prevent foreign objects from entering the
(10) Disconnect the engine ground strap. system.
(11) Remove the air cleaner (Fig. 16).
(12) Disconnect the vacuum purge hose at the fuel
vapor canister tee.
(13) Disconnect the idle speed actuator wire con
nector.
(14) Disconnect the throttle cable and remove it
from the bracket (Fig. 16).
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if equipped
(Fig. 16).

Hose, Fan Shroud & Power Steering Pump
(28) Lift the vehicle and support it with support
stands.
(29) Remove the starter motor.
(30) Remove the flywheel housing access cover.
(31) Remove the engine support cushion-to-bracket
through bolts.
(32) Disconnect the exhaust pipe from the mani
fold.
Fig. 16 Fuel Line Quick-Connect Couplings, Air (33) Remove the upper flywheel housing bolts and
Cleaner Assembly, Throttle & Speed Control Cables loosen the bottom bolts.
(17) Disconnect the oxygen ( 0 ) sensor wire con
2 (34) Lower the vehicle.
nector. (35) Attach a lifting device to the engine.
(18) Remove the upper radiator hose and coolant (36) Raise the engine off the front supports.
recovery hose (Fig. 17). (37) Place a support stand under the flywheel
(19) Disconnect lower radiator hoses at the radia housing.
tor. (38) Remove the remaining flywheel housing bolts.
(20) Disconnect the coolant hoses from the rear of (39) Lift the engine out of the engine compartment
the intake manifold and thermostat housing. and install on an engine stand.
if 4.0L ENGINE 9 - 57
INSTALLATION (29) Install the fuel line bracket to the intake

(1) Lift the engine off the stand and lower it into manifold.
the engine compartment. For easier installation, it (30) Connect all fuel injection wire connections.
may be useful to remove the engine support cushions (31) Install the engine ground strap.
from the engine support brackets as an aide for (32) Connect the ignition coil wire connector.
alignment of the engine-to-transmission. (33) Remove the coolant temperature sending unit
(2) Insert the transmission shaft into the clutch to permit air to escape from the block. Fill the cool
spline. ing system with coolant. Install the coolant tempera
(3) Align the flywheel housing with the engine. ture sending unit when the system is filled.
(4) Install and finger tighten the flywheel housing (34) If equipped with power steering:
lower bolts. (a) Remove the protective caps
(5) Install the engine support cushions (if re (b) Connect the hoses to the fittings at the steer
moved). ing gear. Tighten the nut to 52 N-m (38 ft. lbs.)
(6) Remove the support stand from beneath the fly torque.
wheel housing. (c) Fill the pump reservoir with fluid.
(7) Lower the engine and engine support cushions (35) Install the battery and connect the battery ca
onto the engine compartment brackets. Ensure that bles.
the bolt holes are aligned. Install the bolts and (36) Install the air cleaner bonnet to the throttle
tighten to 65 N-m (48 ft. lbs.) torque. body.
(8) Remove the engine lifting device. (37) Install the air cleaner.
(9) Raise the vehicle. (38) Lower the hood and secure in place.
(10) Attach the exhaust pipe to the manifold. In (39) Start the engine and inspect for leaks.
stall and tighten the nuts to 31 N-m (23 ft. lbs.) (40) Stop the engine and check the fluid levels.
torque. Add fluid, as required.
(11) Install the flywheel housing access cover.
(12) Install the remaining flywheel housing bolts. ENGINE CYLINDER HEAD C0¥ER
Tighten the bolts to 38 N-m (28 ft. lbs.) torque. A cured gasket is part of the engine cylinder head
(13) Install the starter motor and connect the ca cover.
ble. Tighten the bolts to 45 N-m (33 ft. lbs.) torque.
(14) Lower the vehicle. REMOVAL
(15) Connect the coolant hoses and tighten the (1) Disconnect negative cable from battery.
clamps. (2) Disconnect the Crankcase Ventilation (CCV)
(16) Remove the pulley-to-water pump flange vacuum hose from engine cylinder head cover (Fig.
alignment capscrew and install the fan and spacer or 1).
Tempatrol fan assembly. (3) Disconnect the fresh air inlet hose from the en
gine cylinder head cover (Fig. 1).
(17) Tighten the serpentine drive belt according to
(4) Remove the engine cylinder head cover mount
the specifications listed in Group 7, Cooling System.
ing bolts.
(18) Install the fan shroud and radiator (refer to
Group 7, Cooling System for the proper procedure).
(19) Connect the radiator hoses.
(20) Connect the throttle valve rod and retainer.
(21) Connect the throttle cable and install the rod.
(22) Install the throttle valve rod spring.
(23) Connect the speed control cable, if equipped.
(24) Connect the oxygen ( 0 ) sensor wire connec
2
tor.
(25) Install the vacuum hose and check valve on
the brake booster.
(26) Connect the coolant temperature sensor wire
connector.
(27) Connect the idle speed actuator wire connec
tor.
(28) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem
bly fits securely over the fuel lines by giving the fuel
lines a firm tug. Fig. 1 Engine Cylinder Head Cover
9 - 58 4 J L ENGINE — — —
CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
a
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original grey gasket material should NOT be
removed. If sections of the gasket material are miss
ing or are compressed, replace the engine cylinder
head cover. However, sections with minor damage
such as small cracks, cuts or chips may be repaired
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow
the gasket material to cure prior to engine cylinder
head cover installation.
INSTALLATION
(1) If a replacement cover is installed, transfer the Fig. 2 Rocker Arm Assembly
CCV valve grommet and oil filler cap from the orig
inal cover to the replacement cover. Inspect each push rod end for excessive wear and
(2) Install engine cylinder head cover. Tighten the replace as required. If any push rod is excessively
mounting bolts to 9 N-m (75 in. lbs.) torque. worn because of lack of oil, replace it and inspect the
(3) Connect the CCV hoses (Fig. 1). corresponding hydraulic tappet for excessive wear.
(4) Connect negative cable to battery. Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
ROCKER ARMS the push rod and the flat surface.
This procedure can be done with the engine in or A wear pattern along the length of the push rod is
out of the vehicle. not normal. Inspect the engine cylinder head for ob
struction if this condition exists.
REMOVAL
(2) Remove the capscrews at each bridge and pivot (1) Lubricate the ball ends of the push rods with
assembly (Fig. 2). Alternately loosen the capscrews Mopar Engine Oil Supplement, or equivalent and in
one turn at a time to avoid damaging the bridges. stall push rods in their original locations. Ensure
(3) Check for rocker arm bridges which are caus that the bottom end of each push rod is centered in
ing misalignment of the rocker arm to valve tip area. the tappet plunger cap seat.
(4) Remove the bridges, pivots and corresponding (2) Using Mopar Engine Oil Supplement, or equiv
pairs of rocker arms (Fig. 2). Place them on a bench alent, lubricate the area of the rocker arm that the
in the same order as removed. pivot contacts. Install rocker arms, pivots and bridge
(5) Remove the push rods and place them on a above each cylinder in their originally position.
bench in the same order as removed. (3) Loosely install the capscrews through each
bridge.
CLEANING (4) At each bridge, tighten the capscrews alter
Clean all the components with cleaning solvent. nately, one turn at a time, to avoid damaging the
Use compressed air to blow out the oil passages in bridge. Tighten the capscrews to 28 N-m (21 ft. lbs.)
the rocker arms and push rods. torque.
INSPECTION
Inspect the pivot surface area of each rocker arm. ENGINE CYLINDER HEAD
Replace any that are scuffed, pitted, cracked or ex This procedure can be done with the engine in or
cessively worn. out of the vehicle.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply REMOVAL
pitted. (1) Disconnect negative cable from battery.
WARNING; DO N O T R E M O V E T H E C Y L I N D E R (18) Stuff clean lint free shop towels into the cyl
B L O C K DRAIN P L U G S OR L O O S E N T H E R A D I A T O R inder bores.
DRAIN COCK W I T H T H E S Y S T E M H O T AND P R E S CYLINDER
S U R I Z E D B E C A U S E S E R I O U S B U R N S FROM T H E
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at

the engine thermostat housing. Do not waste reus
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(5) Remove the capscrews, bridge and pivot assem
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2). Retain the
push rods, bridges, pivots and rocker arms in CYLINDER J9009-55
HEAD
the same order as removed.
(7) Loosen the serpentine drive belt at the power Fig. 3 Engine Cylinder Head Assembly
steering pump, if equipped or at the idler pulley (re
CLEANING
fer to Group 7, Cooling System for the proper proce
Thoroughly clean the engine cylinder head and cyl
dure).
inder block mating surfaces. Clean the intake and
(8) If equipped with air conditioning, perform the
engine exhaust manifold and engine cylinder head
following:
mating surfaces. Remove all gasket material and car
(a) Remove the bolts from the A/C compressor
bon.
mounting bracket and set the compressor aside.
Check to ensure that no coolant or foreign material
(b) Remove the air conditioner compressor
has fallen into the tappet bore area.
bracket bolts from the engine cylinder head.
Remove the carbon deposits from the combustion
(c) Loosen the through bolt at the bottom of the
bracket. chambers and top of the pistons.
(9) If equipped, disconnect the power steering INSPECTION
pump bracket. Set the pump and bracket aside. Do
Use a straightedge and feeler gauge to check the
not disconnect the hoses.
flatness of the engine cylinder head and block mat
(10) Remove the fuel lines and vacuum advance
ing surfaces.
hose.
(11) Remove the intake and engine exhaust mani INSTALLATION
folds from the engine cylinder head (refer to Group The engine cylinder head gasket is a composition
11, Exhaust System and Intake Manifold for the
gasket. The gasket is to be installed DRY. DO NOT
proper procedures).
use a gasket sealing compound on the gasket.
(12) Disconnect the ignition wires and remove the
If the engine cylinder head is to be replaced and
spark plugs.
(13) Disconnect the temperature sending unit wire the original valves used, measure the valve stem di
connector. ameter. Only standard size valves can be used with a
(14) Remove the ignition coil and bracket assem service replacement engine cylinder head unless the
bly. replacement head valve stem guide bores are reamed
(15) Remove the engine cylinder head bolts. Bolt to accommodate oversize valve stems. Remove all
No. 14 cannot be removed until the head is moved carbon buildup and reface the valves.
forward (Fig. 3). Pull bolt No.14 out as far as it will (1) Remove the shop towels from the cylinder
go and then suspend the bolt in this position (tape bores. Coat the bores with clean engine oil.
around the bolt). (2) Position the engine cylinder head gasket (with
(16) Remove the engine cylinder head and gasket the numbers facing up) onto the cylinder block.
(Fig. 3).
(17) If this was the first time the bolts were re CAUTION: Engine cylinder head bolts should be re
moved, put a paint dab on the top of the bolt. If the used only once. Replace the head bolts if they were
bolts have a paint dab on the top of the bolt or it used before or if they have a paint dab on the top
isn't known if they were used before, discard the of the bolt.
bolts.
(3) With bolt No. 14 held in place (tape around (13) Install the engine cylinder head cover.
bolt), install the engine cylinder head. Remove the (14) Attach the air conditioner compressor mount
tape from bolt No.14. ing bracket to the engine cylinder head and block.
(4) Coat the threads of stud bolt No. 11 with Loctite Tighten the bolts to 40 N-m (30 ft. lbs.) torque.
592 sealant, or equivalent. (15) Attach the air conditioning compressor to the
(5) Tighten the engine cylinder head bolts in se bracket. Tighten the bolts to 27 N-m (20 ft. lbs.)
quence according to the following procedure (Fig. 4): torque.
(a) Tighten all bolts in sequence (1 through 14)
to 30 N-m (22 ft. lbs.) torque. CAUTION: T h e serpentine drive belt must be routed
(b) Tighten all bolts in sequence (1 through 14) correctly. Incorrect routing can cause the water
to 61 N-m (45 ft. lbs.) torque. pump to turn in the opposite direction causing the
(c) Check all bolts to verify they are set to 61 engine to overheat.
(d) Tighten bolts (in sequence): (16) Install the serpentine drive belt and correctly
• Bolts 1 through 10 to 149 N-m (110 ft. lbs.) torque. tension the belt (refer to Group 7, Cooling System for
• Bolt 11 to 136 N-m (100 ft. lbs.) torque. the proper procedure).
• Bolts 12 through 14 to 149 N-m (110 ft. lbs.) (17) Install the air cleaner and ducting.
torque. (18) Install the engine cylinder head cover.
(19) Connect the hoses to the engine thermostat
CAUTION: During the final tightening sequence, housing and fill the cooling system to the specified
bolt No.11 will be tightened to a lower torque than level (refer to Group 7, Cooling Systems for the
the rest of the bolts. DO N O T overtighten bolt proper procedure).
No.11. (20) The automatic transmission throttle linkage
and cable must be adjusted after completing the en
(e) Check all bolts in sequence to verify the cor
gine cylinder head installation (refer to Group 21,
rect torque.
Transmissions for the proper procedures).
(f) If not already done, clean and mark each bolt
(21) Install the temperature sending unit and con
with a dab of paint after tightening. Should you
encounter bolts which were painted in an earlier nect the wire connector.
service operation, replace them. (22) Connect the fuel pipe and vacuum advance
hose.
< ^ Z J FRONT (23) Connect negative cable to battery.
(24) Connect the upper radiator hose and heater
hose at the engine thermostat housing.
(25) Fill the cooling system. Check for leaks.
ENGINE I S O P E R A T I N G . DO NOT S T A N D IN D I R E C T
L I N E W I T H T H E F A N . DO NOT P U T H A N D S N E A R
T H E P U L L E Y S , B E L T S O R FAN. DO N O T W E A R
11 7 3 2 6 10 14
L O O S E CLOTHING.
- - -- " J9209-38
Fig. 4 Engine Cylinder Head Bolt Tightening (26) Operate the engine with the radiator cap off.
Sequence Inspect for leaks and continue operating the engine
until the engine thermostat opens. Add coolant, if re
(6) Install the ignition coil and bracket assembly. quired.
(7) Connect the temperature sending unit wire
connector. VALVE SPRINGS AND OIL SEALS
(8) Install the spark plugs and tighten to 37 N-m This procedure can be done with the engine cylin
(27 ft. lbs.) torque. Connect the ignition wires. der head installed on the block.
(9) Install the intake and engine exhaust mani
folds (refer to Group 11, Exhaust System and Intake REMOVAL
Manifold for the proper procedures). Each valve spring is held in place by a retainer
(10) Install the fuel lines and the vacuum advance and a set of conical valve locks. The locks can be re
hose. moved only by compressing the valve spring.
(11) If equipped, attach the power steering pump (1) Remove the engine cylinder head cover.
and bracket. (2) Remove capscrews, bridge and pivot assemblies
(12) Install the push rods, rocker arms, pivots and and rocker arms for access to each valve spring to be
bridges in the order they were removed. removed.
(3) Remove push rods. Retain the push rods, INSTALLATION

bridges, pivots and rocker arms in the same order
and position as removed. CAUTION: Install oil seals carefully to prevent dam
(4) Inspect the springs and retainer for cracks and age from the sharp edges of the valve spring lock
possible signs of weakening. grove.
(5) Remove the spark plug(s) adjacent to the cylin
der^) below the valve springs to be removed. (1) Lightly push the valve seal over the valve stem
(6) Install a 14 mm (1/2 inch) (thread size) air hose and valve guide boss. Be sure the seal is completely
adaptor in the spark plug hole. An adaptor can be seated on the valve guide boss.
constructed by welding an air hose connection to the (2) Install valve spring and retainer.
body of a spark plug with the porcelain removed. (3) Compress the valve spring with Valve Spring
Compressor Tool MD-998772A and insert the valve
(7) Connect an air hose to the adapter and apply
locks. Release the spring tension and remove the
air pressure slowly. Maintain at least 621 kPa (90
tool. Tap the spring from side-to-side to ensure that
psi) of air pressure in the cylinder to hold the valves
the spring is seated properly on the engine cylinder
against their seats. For vehicles equipped with an air
head.
conditioner, use a flexible air adaptor when servicing
the No.l cylinder. (4) Disconnect the air hose. Remove the adaptor
from the spark plug hole and install the spark plug.
(8) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve (5) Repeat the procedures for each remaining valve
Spring Compressor Tool MD-998772A to compress spring to be removed.
the spring and remove the locks (Fig. 5). (6) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
(9) Remove valve spring and retainer (Fig. 5).
hydraulic valve tappet.
(10) Remove valve stem oil seals (Fig. 5). Note the
valve seals are different for intake and exhaust (7) Install the rocker arms, pivots and bridge at
valves. The top of each seal is marked either INT their original location.
(Intake) or EXH (Exhaust). Do not mix the seals. (8) Tighten the bridge capscrews alternately, one
at a time, to avoid damaging the bridge. Tighten the
VALVE capscrews to 28 N»m (21 ft. lbs.) torque.
LOCKS (9) Install the engine cylinder head cover.
VALVES AND VALVE SPRINGS

This procedure is done with the engine cylinder
head removed from the block.
VALVE REMOVAL
SPRING (1) Remove the engine cylinder head from the cyl
inder block.
(2) Use Valve Spring Compressor Tool
MD-998772A and compress each valve spring.
(3) Remove the valve locks, retainers, springs and
valve stem oil seals. Discard the oil seals.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
EXHAUST the same order as removed.
VALVE
J8909-88 VALVE CLEANING
Clean all carbon deposits from the combustion
Fig. 5 Valve and Valve Components chambers, valve ports, valve stems, valve stem
INSPECTION guides and head.
Inspect the valve stems, especially the grooves. An Clean all grime and gasket material from the en
Arkansas smooth stone should be used to remove gine cylinder head machined gasket surface.
nicks and high spots. INSPECTION
Inspect for cracks in the combustion chambers and
valve ports.
Inspect for cracks on the exhaust seat.
9 - 62 4 . 0 L ENGINE
Inspect for cracks in the gasket surface at each VALVE STEM OIL SEAL REPLACEMENT
coolant passage. Valve stem oil seals are installed on each valve
Inspect valves for burned, cracked or warped heads. stem to prevent rocker arm lubricating oil from en
Inspect for scuffed or bent valve stems. tering the combustion chamber through the valve
Replace valves displaying any damage. guide bores. One seal is marked INT (intake valve)
and the other is marked EXH (exhaust valve).
VALVE REFACING Replace the oil seals whenever valve service is per
(1) Use a valve refacing machine to reface the in formed or if the seals have deteriorated.
take and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 0.787 mm VALVE GUIDES
(0.031 inch) must remain (Fig. 6). 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.
replaced. When the valve stem guide clearance is excessive,
the valve guide bores must be reamed oversize. Ser
VALVE MARGIN
vice valves with oversize stems are available in 0.076
mm (0.003 inch) and 0.381 mm (0.015 inch) incre
ments.
Corresponding oversize valve stem seals are also
available and must be used with valves having 0.381
mm (0.015 inch) oversize stems.
If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the
valve seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE

MEASUREMENT
Valve stem-to-guide clearance may be measured by
INCORRECT VALVE FACING either of the following two methods.
Fig. 6 Valve Facing Margin PREFERRED METHOD:

VALVE SEAT REFACING (1) Remove the valve from the head.
(1) Install a pilot of the correct size in the valve (2) Clean the valve stem guide bore with solvent
guide bore. Reface the valve seat to the specified an and a bristle brush.
gle with a good dressing stone. Remove only enough (3) Insert a telescoping gauge into the valve stem
metal to provide a smooth finish. guide bore approximately 9.525 mm (.375 inch) from
(2) Use tapered stones to obtain the specified seat the valve spring side of the head (Fig. 8).
width when required. (4) Remove and measure telescoping gauge with a
(3) Control valve seat runout to a maximum of micrometer.
0.0635 mm (0.0025 in.)-(Fig. 7). (5) Repeat the measurement with contacts length
wise to engine cylinder head.
(6) Compare the crosswise to lengthwise measure
ments to determine out-of-roundness. If the measure
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.
ALTERNATIVE METHOD:
(1) Use a dial indicator to measure the lateral
movement of the valve stem (stem-to-guide clear
ance). This must be done with the valve installed in
Fig. 7 Measurement of Valve Seat Runout its guide and just off the valve seat (Fig. 9).
TORQUE W R E N C H
GAUGE
VALVE SPRING
TESTER TOOL
VALVE
VALVE SPRING
STEM
GUIDE
J9009-18
CYLINDER
Fig. 10 Valve Spring Tester C-647
HEAD INSTALLATION
(1) Thoroughly clean the valve stems and the
valve guide bores.
J8909-92 (2) Lightly lubricate the stem.
(3) Install the valve in the original valve guide
Fig. 8 Measurement of Valve Guide Bore Diameter
bore.
(2) Correct clearance is 0.025-0.0762 mm (0.001- (4) Install the replacement valve stem oil seals on
0.003 inch). If indicated movement exceeds the spec the valve stems. If the 0.381 mm (0.015 inch) over
ification ream the valve guide to accommodate an size valve stems are used, oversize oil seals are re
oversize valve stem. quired.
Valve seats must be ground after reaming the (5) Position the valve spring and retainer on the
valve guides to ensure that the valve seat is con engine cylinder head and compress the valve spring
centric to the valve guide. with Valve Spring Compressor Tool MD-998772A.
(6) Install the valve locks and release the tool.
(7) Tap the valve spring from side to side with a
hammer to ensure that the spring is properly seated
at the engine cylinder head. Also tap the top of the
retainer to seat the valve locks.
(8) Install the engine cylinder head.
HYDRAULIC TAPPETS
Retain all the components in the same order as re
moved.
REMOVAL
(2) Remove the bridge and pivot assemblies and
INDICATOR
J9009-16 rocker arms by removing the capscrews at each
bridge. Alternately loosen each capscrew, one turn at
Fig. 9 Measurement of Lateral Movement of Valve a time, to avoid damaging the bridges.
Stem (3) Remove the push rods.
VALVE SPRING TENSION TEST (4) Remove the intake and engine exhaust mani
Use Valve Spring Tester C-647 and a torque folds (refer to Group 11, Exhaust System and Intake
wrench to test each valve spring for the specified ten Manifold for the proper procedure).
sion value (Fig. 10). (5) Remove the engine cylinder head and gasket.
Replace valve springs that are not within specifica (6) Remove the tappets through the push rod open
tions. ings in the cylinder block with Hydraulic Valve Tap
pet Removal/Installation Tool C-4129-A (Fig. 11).
HYDRAULIC VALVE TAPPET SNAP
REMOVAL/1 INSTALLATION RING
TOOL
PLUNGER CAP
METERING VALVE
PLUNGER
CHECK
VALVE
SEAT
CHECK
VALVE
CHECK
VALVE
SPRING
CHECK
VALVE
J8909-96
RETAINER
Fig. 11 Hydraulic Valve Tappet Removal/Installation PLUNGER

Tool C-4129-A RETURN
SPRING
DISASSEMBLE
Place the components of each tappet in a separate TAPPET
location. This will greatly assist in the installation BODY J8909-97
operation.
(1) Release the snap ring. Fig. 12 Hydraulic Tappet Assembly
(2) Remove the following from the tappet body LEAK-DOWN TEST
(Fig. 12): After cleaning, inspection and assembly, test each
(a) The plunger cap. tappet for specified leak-down rate tolerance to en
(b) The metering valve. sure zero-lash operation (Fig. 13).
(c) The plunger. Swing the weighted arm of the hydraulic valve tap
(d) The check valve assembly. pet tester away from the ram of the Leak-Down
(e) The plunger return spring. Tester 7980.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) di
CLEANING ameter ball bearing on the plunger cap of the tappet.
Clean the components of each tappet assembly in (2) Lift the ram and position the tappet (with the
cleaning solvent to remove all varnish, gum and ball bearing) inside the tester cup.
sludge deposits. (3) Lower the ram, then adjust the nose of the ram
until it contacts the ball bearing. Do not tighten the
INSPECTION hex nut on the ram.
Inspect for indications of scuffing on the side and (4) Fill the tester cup with hydraulic valve tappet
base of each tappet body. test oil until the tappet is completely submerged.
Inspect each tappet base for concave wear with a (5) Swing the weighted arm onto the push rod and
straightedge positioned across the base. If the base is pump the tappet plunger up and down to remove air.
concave, the corresponding lobe on the camshaft is When the air bubbles cease, swing the weighted arm
also worn. Replace the camshaft and defective tap away and allow the plunger to rise to the normal po
pets. sition.
(6) Adjust the nose of the ram to align the pointer
ASSEMBLY with the SET mark on the scale of the tester and
(1) Install the plunger return spring, check valve tighten the hex nut.
assembly, plunger, metering valve and the plunger (7) Slowly swing the weighted arm onto the push
cap in tappet body. rod.
(2) Compress the plunger assembly by exerting (8) Rotate the cup by turning the handle at the
force on the plunger cap with the push rod and in base of the tester clockwise one revolution every 2
stall snap ring. seconds.
(9) Observe the leak-down time interval from the and rocker arms from above the No.l cylinder.
instant the pointer aligns with the START mark on Alternately loosen each capscrew, one turn at a
the scale until the pointer aligns with the 0.125 time, to avoid damaging the bridge.
mark. A normally functioning tappet will require 20- Rotate the crankshaft until the No.6 piston is at
110 seconds to leak-down. Discard tappets with leak- top dead center (TDC) on the compression stroke.
down time interval not within this specification. Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90°.
Install a dial indicator on the end of the No.l cyl
inder intake valve push rod. Use rubber tubing to se
cure the indicator stem on the push rod.
Set the dial indicator pointer at zero.
Rotate the crankshaft clockwise (viewed from the
front of the engine) until the dial indicator pointer
indicates 0.305 mm (0.012 inch) travel distance (lift).
The timing notch index on the vibration damper
should be aligned with the TDC mark on the timing
degree scale.
If the timing notch is more than 13 mm (1/2 inch)
away from the TDC mark in either direction, the
valve timing is incorrect.
If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
Fig. 13 Leak-Down Tester 7980 the camshaft because of pin failure. A spring pin is
INSTALLATION available for service replacement.
It is not necessary to charge the tappets with en
gine oil. They will charge themselves within a very VIBRATION DAMPER
short period of engine operation.
(1) Dip each tappet in Mopar Engine Oil Supple REMOVAL
ment, or equivalent. (1) Disconnect negative cable from battery.
(2) Use Hydraulic Valve Tappet Removal/Installa (2) Remove the serpentine drive belt and fan
tion Tool C-4129-A to install each tappet in the same shroud.
bore from where it was originally removed. (3) Remove the vibration damper retaining bolt
(3) Install the exhaust and intake manifolds (refer and washer.
to Group 11, Exhaust System and Intake Manifold (4) Use Vibration Damper Removal Tool 8068 to
for the proper procedure). remove the damper from the crankshaft (Fig. 1).
(4) Install the engine cylinder head and gasket.
(5) Install the push rods in their original locations.
(6) Install the rocker arms and bridge and pivot
assemblies at their original locations. Loosely install
the capscrews at each bridge.
(7) Tighten the capscrews alternately, one turn at
a time, to avoid damaging the bridges. Tighten the
capscrews to 28 N»m (21 ft. lbs.) torque.
(8) Pour the remaining Mopar Engine Oil Supple
ment, or equivalent over the entire valve actuating
assembly. The Mopar Engine Oil Supplement, or
equivalent must remain with the engine oil for at
least 1 609 km (1,000 miles). The oil supplement
need not be drained until the next scheduled oil
change.
Fig. 1 Vibration Damper Removal Tool 8068
VALVE TIMING
Disconnect the spark plug wires and remove the INSTALLATION
spark plugs. (1) With the key in position, align the key slot of
Remove the engine cylinder head cover. the vibration damper hub with the crankshaft key
Remove the capscrews, bridge and pivot assembly, and tap the damper onto the crankshaft.
I - 66 4 J L ENGINE J
(2) Install the vibration damper retaining bolt and D R A W SCREW TOOL
washer.
(8) Tighten the damper retaining bolt to 108 N*m
(4) Install the serpentine drive belt and tighten to
the specified tension (refer to Group 7, Cooling Sys
tems for the proper specifications and procedures).
TIMING CASE COVER OIL SEAL REPLACEMENT

This procedure is done with the timing case cover
installed.
(2) Remove the serpentine drive belt. SEAL
INSTALLATION J9009-24
TOOL
(4) Remove the radiator shroud.
(5) Remove the oil seal (Fig. 2). Fig. 3 Timing Case Cover Oil Seal Installation
OIL SEAL TIMING CASE COVER
REMOVER TOOL
REMOVAL
(2) Remove the vibration damper (Fig. 4).
(3) Remove the fan and hub assembly and remove
the fan shroud.
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (if equipped) and
J9009-29
generator bracket assembly from the engine cylinder
head and move to one side.
Fig. 2 Timing Case Cover OH Seal Removal (6) Remove the oil pan-to-timing case cover bolts
(6) Position the replacement oil seal on Timing and timing case cover-to-cylinder block bolts.
Case Cover Alignment and Seal Installation Tool (7) Remove the timing case cover and gasket from
6139 with seal open end facing inward. Apply a light the engine. Make sure the tension spring and thrust
film of Perfect Seal, or equivalent, on the outside di pin do not fall out of the preload bolt.
ameter of the seal. Lightly coat the crankshaft with (8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 4).
engine oil.
(7) Position the tool and seal over the end of the VIBRATION TIMING
CASE
crankshaft and insert a draw screw tool into Seal In DAMPER
COVER
PULLEY
stallation Tool 6139 (Fig. 3). Tighten the nut against
the tool until it contacts the cover.
(8) Remove the tools. Apply a light film of engine
oil on the vibration damper hub contact surface of
the seal. OIL
(9) With the key inserted in the keyway in the SLINGER
bolt. Lubricate and tighten the bolt to 108 N*m (80
ft. lbs.) torque.
(10) Install the serpentine belt and tighten to the
specified tension (refer to Group 7, Cooling Systems
for the proper specifications and procedures). CRANKSHAFT
J9009-21
(11) Install the radiator shroud. OIL SEAL
(12) Connect negative cable to battery. Fig. 4 Timing Case Cover Components
CLEANING
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
INSTALLATION TIMING CHAIN AND SPROCKETS
(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward REMOVAL
the inside of the cover. Support the cover at the seal (1) Disconnect negative cable from battery.
area while installing the seal. Force it into position (2) Remove the fan and shroud.
with Seal Installation Tool 6139. (3) Remove the serpentine drive belt.
(2) Position the gasket on the cylinder block. (4) Remove the crankshaft vibration damper.
(3) Position the timing case cover on the oil pan (5) Remove the timing case cover.
gasket and the cylinder block. Make sure the tension (6) Rotate crankshaft until the "0" timing mark is
spring and thrust pin are in place in the camshaft closest to and on the center line with camshaft
preload bolt. sprocket timing mark (Fig. 6).
(4) Insert Timing Case Cover Alignment and Seal TIMING CRANKSHAFT
Installation Tool 6139 in the crankshaft opening in MARKS SPROCKET
the cover (Fig. 5).
" T I M I N G CASE
COVER ALIGNMENT
A N D SEAL INSTALLATION
TOOL
CAMSHAFT
SPROCKET J9009-61
Fig. 6 Crankshaft/Camshaft Alignment
J9009-23
(7) Remove the oil slinger from the crankshaft.
(8) Remove the tension spring and thrust pin from
Fig. 5 Timing Case Cover Alignment and Seal the preload bolt (Fig. 7). Remove the camshaft
Installation Tool 6139 sprocket retaining preload bolt and washer.
(5) Install the timing case cover-to-cylinder block CAMSHAFT WASHER TENSION
and the oil pan-to-timing case cover bolts. SPROCKET SPRING
(6) Tighten the cover-to-block bolts to 7 N-m (60
in. lbs.) torque. Tighten the oil pan-to-cover 1/4 inch
bolts to 13 N»m (114 in. lbs.) torque. Tighten the oil
pan-to-cover 5/16 inch bolts to 18 N*m (156 in. lbs.) THRUST
torque. PIN
(7) Remove the cover alignment tool.
(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) With the key inserted in the keyway in the
bolt. Lubricate and tighten the bolt to 108 N-m (80
ft. lbs.) torque. PRELOAD
(10) Install the A/C compressor (if equipped) and BOLT J9109-177
generator bracket assembly.
Fig. 7 Camshaft Sprocket Preload Bolt
(11) Install the engine fan and hub assembly and
shroud. (9) Remove the crankshaft sprocket, camshaft
(12) Install the serpentine drive belt and tighten to sprocket and timing chain as an assembly.
obtain the specified tension. Installation of the timing chain with the timing
(13) Connect negative cable to battery. marks on the crankshaft and camshaft sprockets
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 (11) Connect negative cable to battery.
chain has 48 pins. A chain with more than 48 pins
will cause excessive slack. CAMSHAFT
Assemble the timing chain, crankshaft sprocket
WARNING: T H E COOLANT IN A R E C E N T L Y O P E R
and camshaft sprocket with the timing marks
aligned (Fig. 6). A T E D ENGINE I S H O T AND P R E S S U R I Z E D . R E
L E A S E T H E P R E S S U R E B E F O R E REMOVING T H E
(1) With the key in the keyway on the crankshaft,
DRAIN COCK, CAP AND DRAIN P L U G S .
install the assembly on the crankshaft and camshaft.
(2) Install the camshaft sprocket retaining preload
bolt and washer (Fig. 7). Tighten the preload bolt to
(2) Drain the cooling system. Do not waste reus
108 N«m (80 ft. lbs.) torque.
able coolant. If the solution is clean, drain it into a
clean container for reuse.
sprocket timing mark as shown in Fig. 8. Count the (3) Remove the radiator or radiator/condenser, if
number of chain pins between the timing marks of equipped with A/C (refer to Group 7, Cooling System
both sprockets. There must be 15 pins. for the proper procedure).
(4) Remove the air conditioner condenser and re
CAMSHAFT
SPROCKET
ceiver/drier assembly as a charged unit, if equipped
(refer to Group 24, Heating and Air Conditioning).
(5) Remove the distributor cap and mark the posi
tion of the rotor.
(6) Remove the distributor and ignition wires.
(9) Remove the push rods.
(10) Remove the engine cylinder head and gasket.
(11) Remove the hydraulic valve tappets from the
engine cylinder head.
(14) Remove the timing chain and sprockets.
(15) Remove the front bumper and/or grille, as re
quired.
(16) Remove the camshaft (Fig. 9).
CRANKSHAFT
SPROCKET J9209-16
Fig. 8 Verify Sprocket/Chain installation

(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover.
(6) Lubricate the tension spring, thrust pin and
pin bore in the preload bolt with Mopar Engine Oil
Supplement, or equivalent. Install the spring and
thrust pin in the preload bolt head (Fig. 6).
CAMSHAFT
(7) Install the timing case cover and gasket.
(8) With the key in the keyway on the crankshaft,
install the vibration damper, washer and bolt. Lubri CRANKSHAFT
cate and tighten the bolt to 108 N-m (80 ft. lbs.) J9009-31
torque.
(9) Install the serpentine drive belt and tighten to Fig. 9 Camshaft
the specified tension (refer to Group 7, Cooling Sys INSPECTION
tem for the proper procedure). Inspect the cam lobes for wear.
(10) Install the fan and hub (or Tempatrol fan) as Inspect the bearing journals for uneven wear pat
sembly. Install the shroud. tern or finish.
Inspect the bearings for wear. should be aligned with the No.l cylinder spark plug
Inspect the distributor drive gear for wear. terminal on the cap when the distributor housing is
If the camshaft appears to have been rubbing fully seated on the cylinder block.
against the timing case cover, examine the oil pres During installation, lubricate the hydraulic
sure relief holes in the rear cam journal. The oil valve tappets and all valve components with Mo
pressure relief holes must be free of debris. par Engine Oil Supplement, or equivalent. The
Mopar Engine Oil Supplement, or equivalent
INSTALLATION must remain with the engine oil for at least 1 609
(1) Lubricate the camshaft with Mopar Engine Oil km (1,000 miles). The oil supplement need not be
Supplement, or equivalent.
drained until the next scheduled oil change.
(2) Carefully install the camshaft to prevent dam
(16) Install the A/C condenser and receiver/drier
age to the camshaft bearings (Fig. 9).
(3) Install the timing chain, crankshaft sprocket assembly, if equipped (refer to Group 24, Heating
and camshaft sprocket with the timing marks and Air Conditioning).
aligned.
C A U T I O N : Both s e r v i c e v a l v e s must b e o p e n e d be
(4) Install the camshaft sprocket retaining preload
f o r e the air c o n d i t i o n i n g s y s t e m is o p e r a t e d .
bolt. Tighten the bolt to 108 N-m (80 ft. lbs.) torque.
(5) Lubricate the tension spring, the thrust pin (17) Install the radiator, connect the hoses and fill
and the pin bore in the preload bolt with Mopar En
the cooling system to the specified level (refer to
gine Oil Supplement, or equivalent. Install the
Group 7, Cooling System for the proper procedure).
spring and thrust pin in the preload bolt head.
(18) Check the ignition timing and adjust as nec
(6) Install the timing case cover with a replace
ment oil seal (Fig. 10). essary.
(7) Install the vibration damper (Fig. 10). (19) Install the grille and bumper, if removed.
VIBRATION TIMING
DAMPER CASE
CAMSHAFT P I N REPLACEMENT
PULLEY COVER
REMOVAL
W A R N I N G : DO N O T L O O S E N T H E R A D I A T O R
D R A I N C O C K WITH T H E S Y S T E M H O T A N D P R E S
OIL S U R I Z E D B E C A U S E SERIOUS B U R N S F R O M COOL
SLINGER
ANT C A N OCCUR.

(2) Drain the radiator. Do not waste reusable cool
ant. Drain the coolant into a clean container.
(3) Remove the fan and shroud.
CRANKSHAFT
J9009-21 (4) Disconnect the radiator overflow tube, radiator
OIL SEAL
hoses, automatic transmission fluid cooler pipes (if
Fig. 10 Timing Case Cover Components equipped).
(5) Remove the radiator.
(8) Install the hydraulic valve tappets. (6) If equipped with air conditioning;
(9) Install the engine cylinder head.
(10) Install the push rods. C A U T I O N : D O N O T l o o s e n o r d i s c o n n e c t any air
(11) Install the rocker arms and pivot and bridge c o n d i t i o n e r s y s t e m fittings. M o v e t h e c o n d e n s e r
assemblies. Tighten each of the capscrews for each and receiver/drier a s i d e a s a c o m p l e t e a s s e m b l y .
bridge alternately, one turn at a time, to avoid dam
aging the bridge. (a) Remove the A/C compressor serpentine drive
(12) Install the engine cylinder head cover. belt idler pulley.
(13) Install the serpentine drive belt and tighten to (b) Disconnect and remove the generator.
the specified tension (refer to Group 7, Cooling Sys (c) Remove the A/C condenser attaching bolts
tem for the proper procedure). and move the condenser and receiver/drier assem
(14) Rotate the crankshaft until the No.l piston is bly up and out of the way.
at the TDC position on the compression stroke. (7) Remove the serpentine drive belt.
(15) Install the distributor, cap and ignition wires. (8) Remove the crankshaft vibration damper.
Install the distributor so that the rotor is aligned (9) Remove the timing case cover. Clean the gas
with the mark made during removal. The rotor ket material from the cover.
9 - 70 4 J L ENGINE J
(10) R e m o v e the thrust pin and tension spring bearing (smallest). This permits easier removal and
from the preload bolt h e a d . installation of the camshaft. The camshaft bearings
(11) Rotate crankshaft until t h e crankshaft are pressure lubricated.
sprocket timing m a r k is closest to a n d on the center It is not advisable to attempt to replace cam
line with the camshaft sprocket timing mark (Fig. shaft bearings unless special removal and instal
11). lation tools are available.
CRANKSHAFT
Camshaft end play is maintained by the load
TIMING
MARKS SPROCKET placed on the camshaft by the sprocket preload bolt
tension spring and thrust pin.
INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install the camshaft sprocket, crankshaft
sprocket and timing chain with the timing marks
aligned (Fig. 11).
CAMSHAFT chain, turn the crankshaft to position the camshaft
SPROCKET J9009-61
sprocket timing mark as shown in Fig. 12. Count the
Fig. 11 liming Chain Alignment number of chain pins between the timing marks of
both sprockets. There must be 15 pins.
(12) Remove the cam-shaft sprocket preload retain
ing bolt and washer. CAMSHAFT
SPROCKET
(13) Remove the crankshaft oil slinger.
(14) Remove the sprockets and chain as an assem
bly.
CAUTION: The following procedural step m u s t be

accomplished to prevent t h e c a m s h a ft from damag
ing the rear c a m s h a f t plug during pin installation.
(15) Inspect the damaged camshaft pin.

(16) If the pin is a spring-type pin, remove the bro
ken pin by inserting a self-tapping screw into the pin
and carefully pulling the pin from the camshaft.
(17) If the pin is a dowel-type pin, center-punch it.
Ensure the exact center is located when center-
punching the pin.
CAUTION: C o v e r the o p e n e d oil p a n area to prevent

metal chips f r o m entering the p a n .
CRANKSHAFT
(18) Drill into the pin center with a 4 mm (5/32 SPROCKET J9209-16
inch) drill bit.
Fig. 12 Verify Crankshaft/Camshaft Installation
(19) Insert a self-tapping screw into the drilled pin
and carefully pull the pin from the camshaft. (6) Install the crankshaft oil slinger.
(7) Tighten the camshaft sprocket preload bolt to
CAMSHAFT BEARINGS 108 N-m (80 ft. lbs.) torque.
The camshaft rotates within four steel-shelled, bab (8) Check the valve timing.
bitt-lined bearings that are pressed into the cylinder (9) Lubricate the tension spring, the thrust pin
block and then line reamed. The camshaft bearing and the pin bore in the preload bolt with Mopar En
bores and bearing diameters are not the same size. gine Oil Supplement, or equivalent. Install the
They are stepped down in 0.254 mm (0.010 inch) in spring and thrust pin in the preload bolt head.
crements from the front bearing (largest) to the rear (10) Coat both sides of the replacement timing case
cover gasket with gasket sealer. Apply a 3 mm (1/8
inch) bead of Mopar Silicone Rubber Adhesive Seal OIL PAN

ant, or equivalent to the joint formed at the oil pan
and cylinder block. REMOVAL
(11) Position the timing case cover on the oil pan (1) Disconnect negative cable from battery.
gasket and the cylinder block. (2) Raise the vehicle.
(12) Place Timing Case Cover Alignment and Seal (3) Remove the oil pan drain plug and drain the
Installation Tool 6139 in the crankshaft opening in engine oil.
the cover (Fig. 13). (4) Disconnect the exhaust pipe at the exhaust
manifold.
TIMING CASE
(5) Disconnect the exhaust hanger at the catalytic
COVER ALIGNMENT
A N D SEAL INSTALLATION converter and lower the pipe.
TOOL (6) Remove the starter motor.
(7) Remove the engine flywheel/transmission
torque converter housing access cover.
(8) If equipped with an oil level sensor, disconnect
the sensor.
(9) Position a jack stand directly under the engine
vibration damper.
(10) Place a piece of wood (2 x 2) between the jack
stand and the engine vibration damper.
(11) Remove the engine mount through bolts.
(12) Using the jack stand, raise the engine until
J9009-23 adequate clearance is obtained to remove the oil pan.
(13) Remove the oil pan bolts. Carefully slide the
Fig. 13 Timing Case Cover Alignment and Seal oil pan and gasket to the rear. If equipped with an
Installation Tool 6139 oil level sensor, take care not to damage the sensor.
(13) Install the timing case cover-to-cylinder block
CLEANING
bolts. Install the oil pan-to-timing case cover bolts.
(14) Tighten the cover-to-block bolts to 7 N-m (60 Clean the block and pan gasket surfaces.
in. lbs.) torque. Tighten the oil pan-to-cover 1/4 inch
INSTALLATION
bolts to 13 N-m (114 in. lbs.) torque. Tighten the oil
(1) Fabricate 4 alignment dowels from 1 1/2 x 1/4
pan-to-cover 5/16 inch bolts to 18 N-m (156 in. lbs.)
inch bolts. Cut the head off the bolts and cut a slot
torque.
into the top of the dowel. This will allow easier in
(15) Remove the cover alignment tool and install a stallation and removal with a screwdriver (Fig. 1).
replacement oil seal into the cover.
(16) Install the vibration damper on the crank 1 1/2" x 1/4" BOLT
shaft. H /
(17) Lubricate and tighten the damper bolt to 108
N-m (80 ft. lbs.) torque. I
(18) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive DOWEL
belt idler pulley.
(b) Install the generator.
(c) Install the A/C condenser and receiver/drier
assembly. SLOT J9209-6
(19) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the Fig. 1 Fabrication of Alignment Dowels
specifications and procedures). (2) Install two dowels in the timing case cover. In
(20) Install the radiator. Connect the radiator stall the other two dowels in the cylinder block (Fig.
hoses and automatic transmission fluid cooler pipes,
2).
if equipped. Fill the cooling system.
(3) Slide the one-piece gasket over the dowels and
(21) Install the fan and shroud. onto the block and timing case cover.
(22) Connect negative cable to battery. (4) Position the oil pan over the dowels and onto
the gasket. If equipped with an oil level sensor, take
care not to damage the sensor.
9 - 72 ENGINE
D O W E L HOLES CYLINDER WARNING: U S E E X T R E M E CAUTION W H E N T H E

R E C T L I N E W I T H T H E F A N . DO N O T P U T Y O U R
HANDS N E A R T H E P U L L E Y S , B E L T S O R F A N . DO
NOT W E A R L O O S E CLOTHING.
OIL P U M P
A gear-type oil pump is mounted at the underside
of the cylinder block opposite the No.4 main bearing.
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
(75 psi). In the relief position, the valve permits oil
J9209-17 to bypass through a passage in the pump body to the
inlet side of the pump.
F/flf. 2 Position of Dowels in Cylinder Block Oil pump removal or replacement will not affect
(5) Install the 1/4 inch oil pan bolts. Tighten these the distributor timing because the distributor drive
bolts to 13 N-m (114 in. lbs.) torque. Install the 5/16 gear remains in mesh with the camshaft gear.
inch oil pan bolts (Fig. 3). Tighten these bolts to 18 REMOVAL
N*m (156 in. lbs.) torque. (1) Drain the engine oil.
(2) Remove the oil pan.
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
4).
CAUTION: If the oil pump i s not to be serviced, do

not disturb position of oil inlet tube and strainer as
sembly in pump body. If the tube i s moved within
the pump body, a replacement tube and strainer as
sembly must be installed to assure an airtight seal.
OIL FILTER /
ADAPTOR
Fig. 3 Position of 5/16 inch Oil Pan Bolts
(6) Remove the dowels. Install the remaining 1/4
inch oil pan bolts. Tighten these bolts to 13 N*m (114
in. lbs.) torque.
(7) Lower the engine until it is properly located on
the engine mounts.
(8) Install the through bolts and tighten the nuts
to 65 N«m (48 ft. lbs.) torque.
(9) Lower the jack stand and remove the piece of
wood.
(10) If equipped with an oil level sensor, connect
the sensor.
(11) Install the engine flywheel/transmission
torque converter housing access cover.
(12) Install the engine starter motor.
(13) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(14) Install the oil pan drain plug (Fig. 3). Tighten STRAINER ATTACHING
the plug to 41 N*m (30 ft. lbs.) torque. ASSEMBLY BOLTS J8909-119
(15) Lower the vehicle. Fig. 4 Oil Pump Assembly
(16) Connect negative cable to battery. DISASSEMBLE
(17) Fill the oil pan with engine oil to the specified (1) Remove the cover from the pump body.
level. (2) Check the following clearances:
4.0L ENGINE 9 - 73
J
GEAR END CLEARANCE MEASUREMENT
PREFERRED METHOD:
(a) Place a strip of Plastigage across the full
width of each gear.
(b) Install the pump cover and tighten the bolts
to 8 N»m (70 in. lbs.) torque.
(c) Remove the pump cover and determine the
amount of clearance by measuring the width of
compressed Plastigage with scale on the Plastigage
envelope (Fig. 5).
(d) Correct clearance by this method is 0.051-
inch with 0.002 inch preferred).
(e) If gear end clearance is excessive, replace the
oil pump assembly.
OIL PUMP Fig. 6 Gear End Clearance
GEAR
Measurement—Alternative Method
gears to measure each tooth-to-body clearance in
this manner (Fig. 7).
(b) Correct clearance is 0.051-0.102 mm with
0.051 mm preferred (0.002-0.004 inch with 0.002
inch preferred).
(c) If the gear-to-body clearance is more than
specified, replace oil pump.
STRIP OF P L A S T I G A G E J8909-120
Fig. 5 Gear End Clearance Measurement—Preferred

Method
ALTERNATIVE METHOD:
(a) Place a straightedge across the ends of the
gears and the pump body.
(b) Select a feeler gauge that fits snugly but
freely between the straightedge and the pump body
(Fig. 6).
(c) Correct clearance by this method is 0.051- J8909-122
inch with 0.002 inch preferred). Fig. 7 Gear-to-Body Clearance Measurement
(d) If gear end clearance is excessive, replace the DISASSEMBLE (C0NT»)
oil pump assembly. (3) Remove the cotter pin and slide the spring re
tainer, spring and oil pressure relief valve plunger
GEAR-TO-BODY CLEARANCE MEASUREMENT out of the pump body.
(a) Measure the gear-to-body clearance with both (4) Inspect for binding condition during disassem
gears in place. Insert a feeler gauge between the bly. Clean or replace as necessary.
gear tooth and the inner wall of the pump body di (5) The oil inlet tube and strainer assembly must
rectly opposite the point of gear mesh. Select a be moved to allow removal of the relief valve.
feeler gauge which fits snugly but freely. Rotate
I - 74 4JL ENGINE J
ASSEMBLY PISTONS AND CONNECTING RODS

Two relief valve plunger sizes (standard and over
size) are available. The oversize plunger diameter is REMOVAL
0.254 mm (0.010 inch). (1) Remove the engine cylinder head cover.
(1) Install the oil pressure relief valve plunger, (2) Remove the rocker arms, bridges and pivots.
spring, retainer, and cotter pin. (3) Remove the push rods,
(2) If the position of the inlet tube in the pump (4) Remove the engine cylinder head.
body has been disturbed, install a replacement inlet (5) Position the pistons one at a time near the bot
tube and strainer assembly. Apply a light film of tom of the stroke. Use a ridge reamer to remove the
Permatex No.2 sealant, or equivalent, around the ridge from the top end of the cylinder walls. Use a
end of the tube. Use Oil Pump Inlet Tube Installa protective cloth to collect the cuttings.
tion Tool 7624 to drive the inlet tube into the body (6) Raise the vehicle.
(Fig. 8). BE sure the support bracket is properly (7) Drain the engine oil.
aligned. (8) Remove the oil pan and gasket.
(9) Remove the connecting rod bearing caps and
inserts. Retain in the same order as removed. The
connecting rods and caps are stamped with the corre
sponding cylinder number (Fig. 1).
CONNECTING
ROD CAP
Fig. 8 Inlet Tube Installation Tool 7624

(3) Install the idler gear and drive gear assembly.
CONNECTING ROD J9009-40
(4) Spin the drive gear shaft to ensure a binding
condition does not exist before installing the oil Fig. 1 Stamped Connecting Rods and Caps
pump.
(5) To self-prime the oil pump, fill pump with pe (10) Lower the vehicle until it is about 2 feet from
troleum jelly before installing the oil pump cover. the floor.
DO NOT use grease. CAUTION; Ensure that the connecting rod bolts DO
(6) Apply a thin bead of Mopar Gasket Maker, or NOT scratch the crankshaft journals or cylinder
equivalent, to the top of the pump housing. walls. Short pieces of rubber hose, slipped over the
(7) Install the oil pump cover. Tighten the cover rod bolts will provide protection during removal.
bolts to 8 N*m (70 in. lbs.) torque.
(11) Have an assistant push the piston/connecting
INSTALLATION rod assemblies up and through the top of the cylinder
(1) Install the oil pump on the cylinder block using bores (Fig. 2).
a replacement gasket. Tighten the short bolt to 14
Nmi (10 ft. lbs.) torque and the long bolt to 23 N*m INSPECTION- CONNECTING ROD
(2) Install the oil pan. CONNECTING ROD BEARINGS
(3) Fill the oil pan with oil to the specified level. Inspect the connecting rod bearings for scoring and
bent alignment tabs (Figs. 3 and 4). Check the bear
OIL PUMP PRESSURE ings for normal wear patterns, scoring, grooving, fa
The MINIMUM oil pump pressure is 89.6 kPa (13 tigue and pitting (Fig. 5). Replace any bearing that
psi) at 600 rpm. The MAXIMUM oil pump pressure shows abnormal wear.
is 255-517 kPa (37-75 psi) at 1600 rpm or more. Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
CONNECTING PISTON ABNORMAL CONTACT AREA

ROD C A U S E D BY LOCKING TABS NOT
F U L L Y S E A T E D OR BEING BENT
BLOCK
J8909-128
Fig. 4 Locking Tab Inspection
J8909-166
Fig. 2 Removal of Connecting Rod and Piston

Assembly LOWER UPPER
UPPER MATING EDGES J8909-129

GROOVES CAUSED
BY ROD BOLTS Fig. 5 Scoring Caused by Insufficient Lubrication or
SCRATCHING by Damaged Crankshaft Pin Journal
JOURNAL DURING
INSTALLATION (4) Use piston ring compressor to install the rod
and piston assemblies. The oil squirt holes in the
rods must face the camshaft. The arrow on the piston
crown should point to the front of the engine (Fig. 6).
Verify that the oil squirt holes in the rods face the
camshaft and that the arrows on the pistons face the
WEAR P A T T E R N - front of the engine.
ALWAYS GREATER
ON UPPER BEARING
LOWER J8909-127
Fig. 3 Connecting Rod Bearing Inspection

CONNECTING RODS
Misaligned or bent connecting rods can cause ab
normal wear on pistons, piston rings, cylinder walls,
connecting rod bearings and crankshaft connecting
rod journals. If wear patterns or damage to any of
these components indicate the probability of a mis
aligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con J9009-41
necting rods.
BEARING-TO-JOURNAL CLEARANCE (5) Install the lower bearing insert in the bearing
(1) Wipe the oil from the connecting rod journal. cap. The lower insert must be dry. Place strip of
(2) Use short rubber hose sections over rod bolts Plastigage across full width of the lower insert at the
during installation. center of bearing cap. Plastigage must not crumble
(3) Lubricate the upper bearing insert and install in use. If brittle, obtain fresh stock.
in connecting rod.
9 - 76 4.0L ENGINE j
(6) Install bearing cap and connecting rod on the PLASTIGAGE

journal and tighten nuts to 45 N*m (33 ft. lbs.) SCALE
torque. Do not rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication,
(7) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 7). Refer to En
gine Specifications for the proper clearance. Plasti
gage should indicate the same clearance across
the entire width of the insert. If the clearance
varies, it may be caused by either a tapered
journal, bent connecting rod or foreign material
trapped between the insert and cap or rod.
(8) If the correct clearance is indicated, replace
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation. Fig. 7 Measuring Bearing Clearance with Plastigage
(9) If bearing-to-journal clearance exceeds the spec
ification, install a pair of 0.0254 mm (0.001 inch) un and within specification. A 0.051 mm (0.002 inch)
dersize bearing inserts. All the odd size inserts must undersize insert would reduce the initial clearance
be on the bottom. The sizes of the service replace an additional 0.013 mm (0.0005 inch). The clearance
ment bearing inserts are stamped on the backs of the would then be 0.038 mm (0.0015 inch).
inserts. Measure the clearance as described in the (11) Repeat the Plastigage measurement to verify
previous steps. your bearing selection prior to final assembly.
(10) The clearance is measured with a pair of (12) Once you have selected the proper insert, in
0.0254 mm (0.001 inch) undersize bearing inserts in stall the insert and cap. Tighten the connecting rod
stalled. This will determine if two 0.0254 mm (0.001 bolts to 45 N*m (33 ft. lbs.) torque.
inch) undersize inserts or another combination is
needed to provide the correct clearance (refer to Con SIDE CLEARANCE MEASUREMENT
necting Rod Bearing Fitting Chart). Slide snug-fitting feeler gauge between the con
FOR EXAMPLE: If the initial clearance was necting rod and crankshaft journal flange. Refer to
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) un Engine Specifications for the proper clearance. Re
dersize inserts would reduce the clearance by 0.025 place the connecting rod if the side clearance is not
mm (0.001 inch). The clearance would be 0.002 inch within specification.
CONNECTING ROD BEARING FITTING CHART
Corresponding Connecting Rod

Crankshaft Main Bearing J o u r n a l Bearing I n s e r t Color Code
Color Code and Diameter
Upper Insert Size Lower Insert Size
Yellow—53.2257-53.2079 mm Yellow—Standard
Yellow—Standard
(2.0955-2.0948 in.)
Orange—53.2079-53.1901 mm Blue—Undersize
(2.0948-2.0941 in.) Yel low—Standard
0.025 mm (0.001 in.)
Black—53.1901 -53.1723 mm Blue—Undersize Blue—Undersize

(2.0941-2.0933 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Red—-52.9717-52.9539 mm Red—Undersize
Red—Undersize
. (2.0855-2.0848 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
J9209-49
PISTON FITTING PISTON PIN
MICROMETER METHOD REM0WAL

(1) Measure the inside diameter of the cylinder Piston pins are press-fitted into the connecting rods
bore at a point 58.725 mm (2-5/16 inches) below top and require no locking device.
of bore. (1) Position the piston and connecting rod assem
(2) Measure outside diameter of the piston. Be bly on an arbor press.
cause pistons are cam ground, measure at right an (2) Apply force to a piloted driver and press the
gle to piston pin at center line of pin (Fig. 8). pin completely out of the connecting rod and piston
The difference between cylinder bore diameter and assembly (Fig. 9). Note position of the pin through
piston diameter is piston-to-bore clearance. the gauge window of removal support tool.
GROOVE HEIGHT
A 2.0193-2.0447 mm (0.0795-0.0805 in)
B 4.7752-4.8133 mm (0.1880-0.1895 in)
GROOVE DIAMETER
D -E 87.78-87.90 mm (3.456-3.461 in)
F 87.50-87.75 mm (3.445-3.455 in)
« D, E, F - —H
Fig. 8 Piston Dimensions Fig. 9 Piston Pin Removal/installation

FEELER GAUGE METHOD INSPECTION
(1) Remove the rings from the piston. (1) Inspect the piston pin and pin bore in the con
(2) Insert a long 0.025 mm (0.001 inch) feeler necting rod for nicks and burrs. Remove as neces
gauge into the cylinder bore. sary. Never reuse a piston pin after it has been
(3) Insert the piston, top first, into cylinder bore installed in and removed from a connecting rod.
alongside the feeler gauge. With entire piston in (2) With the pin removed from the piston and con
serted into cylinder bore, the piston should not bind necting rod, clean and dry piston pin bores and the
against feeler gauge. replacement piston pin.
(4) Repeat steps with a long 0.051 mm (0.002 inch) (3) Position the piston so that the pin bore is in
feeler gauge. The piston should bind. vertical position. Insert the pin in bore. At room tem
(5) If the piston binds on 0.025 mm (0.001 inch) perature, the replacement pin should slide com
feeler gauge, the piston is too large or cylinder bore pletely through the pin bore in piston by force of
is too small. If the piston does not bind on 0.051 mm gravity.
(0.002 inch) feeler gauge, the piston is too small for
(4) Replace piston if pin jams in the pin bore.
cylinder bore. Pistons up to 0.102 mm (0.004 inch)
undersize may be enlarged by knurling or shot-peen- INSTALLATION
ing. Replace pistons that are 0.102 mm (0.004 inch)
(1) Insert the piston pin pilot through the piston
or more undersize.
and connecting rod pin bores. Ensure that the arrow
on the piston crown is pointing up (Fig. 10).
(2) Position the pin pilot, piston and connecting
rod on a support with the squirt hole of the connect
ing rod to the left-hand side (Fig, 10).
(3) Insert piston pin through the upper piston pin
Millimeters Inches
bore and into the connecting rod pin bore. 0.025-0.081 0.001-0.0032
NO. 1 COMPRESSION
(4) Position the piloted driver inside the piston pin (0.043 Preferred) (0.0017 Preferred)
(Fig. 9). NO. 2 COMPRESSION 0.025-0.081 0.001-0.0032
(5) Using an arbor press, press the piston pin (0.043 Preferred) (0.0017 Preferred)
through the connecting rod and piston bores until pin Oil Control
0.025-0.241 0.001-0.0095
(0.08 Preferred) (0.003 Preferred)
pilot indexes with mark on the support. The piston
pin requires a 8 900 N (2,000 pounds) press-fit. If lit
tle effort is required to install piston pin in a con
necting rod, or if the rod moves laterally on the pin,
the connecting rod must be replaced.
(6) Remove the piston and connecting rod assembly
from the press. The pin should be centered in the FEELER
connecting rod (±0.792 mm or ±0.0312 inch) and GAUGE
float in the piston pin bore.
CONNECTING
ROD
PISTON
E8909-402
Fig. 11 Ring Side Clearance Measurement

FEELER GAUGE V.
SQUIRT
HOLE
J9009-44
Fig. 10 Correct Alignment—Piston and Connecting
Rod
PISTON RING FITTING
(1) Carefully clean the carbon from all ring
grooves. Oil drain openings in the oil ring groove and
pin boss must be clear. DO NOT remove metal from
J9009-45
the grooves or lands. This will change ring-to-groove
clearances and will damage the ring-to-land seating.
Fig. 12 Ring Gap Measurement
(2) Measure the ring side clearance with a feeler
gauge fitted snugly between the ring land and ring (6) The two compression rings are different and
(Fig. 11). Rotate the ring in the groove. It must move cannot be interchanged (Fig. 14). The top ring is a
freely around circumference of the groove. moly ring (the scraping edge is gray in color). The
(3) Place ring in the cylinder bore and push down second ring is a black cast iron ring (the scraping
with inverted piston to position near lower end of the edge is black in color when new).
ring travel. Measure ring gap with a feeler gauge fit (7) The compression rings can be identified by a
ting snugly between ring ends (Fig. 12). The correct chamfer of either the top or bottom inside edge (Fig.
compression ring end gap is 0.25-0.51 mm (0.010- 14). The rings may also be identified by 1 or 2 dots
0.020 inch). The correct oil control ring end gap is on the top surface of the ring.
0.381-1.397 mm (0.015-0.055 inch). (8) The second compression ring (black cast iron)
(4) Position the ring gaps and install piston rings has a chamfer on the BOTTOM of the inside edge
(Fig. 13). (Fig. 15). This ring may also have 2 dots located on
(5) Install the oil control rings according to in the top surface.
structions in the package. It is not necessary to use a (9) Using a ring installer, install the second com
tool to install the upper and lower rails. Insert ex pression ring with the chamfer facing down (Fig. 16).
pander ring first, then side rails The dots will be facing up.
TOP COMPRESSION RING SECOND COMPRESSION RING
(BLACK CAST IRON)
CHAMFER
BOTTOM
COMPRESSION
RING
TOP OIL
CONTROL RAIL
OIL RAIL
EXPANDER
BOTTOM OIL TWO

CONTROL RAIL
DOTS J9009-46
IMAGINARY LINE
THROUGH CENTER Fig. 15 Second Compression Ring Identification
OF PISTON SKIRT
IMAGINARY LINE
PARALLEL TO
PISTON PIN
RING GAP POSITION MAY

VARY ± 2 0 ° FROM
POSITION ILLUSTRATED
J9109-209
Fig. 13 Ring Gap Position

COMPRESSION
TOP COMPRESSION
RING RING
RING EXPANDER J9009-47
RECOMMENDED
Fig. 16 Compression Ring Installation

(11) Using a ring installer, install the top ring
with the chamfer facing up. The dot will be facing
up.
SECOND (12) Position the ring end gaps on the piston.

COMPRESSION
RING CLEANING
Clean the cylinder bores thoroughly. Apply a light
film of clean engine oil to the bores with a clean lint-
free cloth.
INSTALLATION
(1) Install the piston rings on the pistons if re
moved.
J8909-139 (2) Lubricate the piston and rings with clean en
gine oil.
Fig. 14 Compression Ring Location
(10) The top compression ring (the scraping edge is CAUTION; Ensure that connecting rod bolts DO
gray in color) has a chamfer on the TOP of the inside NOT scratch the crankshaft journals or cylinder
edge. This ring has one dot located on the top sur walls. Short pieces of rubber hose slipped over the
face. connecting rod bolts will provide protection during
installation.
I - 80 4 J L ENGINE 4
(3) Use a piston ring compressor to install the con (8) Lower the vehicle.
necting rod and piston assemblies through the top of (9) Install the engine cylinder head, push rods,
the cylinder bores (Fig. 17). rocker arms, bridges, pivots and engine cylinder head
(4) Ensure the arrow on the piston top points to cover.
the front of the engine (Fig. 17).
(10) Fill the crankcase with engine oil.
CRANKSHAFT MAIN BEARINGS

REMOVAL
(2) Remove the spark plugs.
(4) Remove the oil pan and oil pump.
(5) Remove only one main bearing cap and lower
insert at a time (Fig. 1).
CONNECTING
ROD JOURNAL
J9009-41

Each bearing insert is fitted to its respective jour
nal to obtain the specified clearance between the
bearing and the journal. In production, the select fit
is obtained by using various-sized, color-coded bear
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
The rod journal is identified during the engine pro
duction by a color-coded paint mark on the adjacent
cheek or counterweight toward the flange (rear) end
of the crankshaft. The color codes used to indicate
journal sizes are listed in the Connecting Rod Bear
ing Fitting Chart. MAIN BEARING CAPS J8909-144
different sizes may be used as a pair (refer to Con Fig. 1 Removing Main Bearing Caps and Lower
necting Rod Bearing Fitting Chart). A standard size Inserts
(6) Remove the lower insert from the bearing cap.
mm (0.001 inch) undersize insert to reduce clearance
(7) Remove the upper insert by LOOSENING (DO
0.013 mm (0.0005 inch).
NOT REMOVE) all of the other bearing caps. Now
CAUTION: Do not intermix bearing caps. Each con insert a small cotter pin tool in the crankshaft jour
necting rod and bearing cap are stamped with the nal oil hole. Bend the cotter pin as illustrated to fab
cylinder number. T h e stamp i s located on a ma ricate the tool (Fig. 2). With the cotter pin tool in
chined surface adjacent to the oil squirt hole that place, rotate the crankshaft so that the upper bear
faces the camshaft side of the cylinder block. ing insert will rotate in the direction of its locking
tab. Because there is no hole in the No.3 main jour
(6) Install the connecting rod bearing caps and in nal, use a tongue depressor or similar soft-faced tool
serts in the same positions as removed. to remove the bearing insert (Fig. 2). After moving
the insert approximately 25 mm (1 inch), it can be
CAUTION: Verify that the oil squirt holes in the rods removed by applying pressure under the tab.
face the camshaft and that the arrows on the pis
(8) Using the same procedure described above, re
tons face the front of the engine.
move the remaining bearing inserts one at a time for
(7) Install the oil pan and gaskets as outlined in inspection.
the installation procedure.
J 4 . 0 L ENGINE 9 - 81
COTTER ward position. The upper main bearing inserts are

PIN grooved to provide oil channels while the lower in
serts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
BEARING for engine production.
INSERT
The main bearing journal size (diameter) is identi
fied by a color-coded paint mark on the adjacent
cheek. The rear main journal, is identified by a color-
coded paint mark on the crankshaft rear flange.
different sizes may be used as a pair. A standard size
mm (0.001 inch) undersize insert to reduce the clear
ance by 0.013 mm (0.0005 inch). Never use a pair
J9009-49
of bearing inserts with greater than a 0.025 mm
Fig. 2 Removing Upper Inserts (0.001 inch) difference in size (Fig. 4).
INSPECTION Insert Correct Incorrect
Wipe the inserts clean and inspect for abnormal
Upper Standard Standard
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 3).
0 . 0 2 5 mm ( 0 . 0 0 1 in.) 0 . 0 5 1 mm ( 0 . 0 0 2 in.)
UPPER Lower
INSERT Undersize Undersize
N O WEAR IN
T H I S AREA
L O W AREA
IN BEARING J9109-179
LINING
Fig. 4 Bearing Insert Pairs
When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block)
or all on the bottom (in main bearing cap).
Once the bearings have been properly fitted, pro
LOWER
INSERT ceed to Crankshaft Main Bearing—Installation.
HEAVIER W E A R BEARING-T0-J0URNAL CLEARANCE (CRANKSHAFT

PATTERN O N
J9009-90
INSTALLED)
L O W E R INSERT
When using Plastigage, check only one bearing
Fig. 3 Main Bearing Wear Patterns clearance at a time.
Install the grooved main bearings into the cylinder
If any of the crankshaft journals are scored,
block and the non-grooved bearings into the bearing
remove the engine for crankshaft repair.
caps.
Inspect the back of the inserts for fractures, scrap Install the crankshaft into the upper bearings dry.
ings or irregular wear patterns. Place a strip of Plastigage across full width of the
Inspect the upper insert locking tabs for damage. crankshaft journal to be checked.
Replace all damaged or worn bearing inserts. Install the bearing cap and tighten the bolts to 108
FITTING (CRANKSHAFT INSTALLED) DO NOT rotate the crankshaft. This will cause
The main bearing caps, numbered (front to rear) the Plastigage to shift, resulting in an inaccurate
from 1 through 7 have an arrow to indicate the for reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
9 - 82 4 . 0 L ENGINE J
Remove the bearing cap. Determine the amount of If the clearance exceeds specification using a pair
clearance by measuring the width of the compressed of 0.051 mm (0.002 inch) undersize bearing inserts,
Plastigage with the scale on the Plastigage envelope measure crankshaft journal diameter with a mi
(Fig. 5). Refer to Engine Specifications for the proper crometer. If the journal diameter is correct, the
clearance. crankshaft bore in the cylinder block may be mis
aligned, which requires cylinder block replacement
PLASTIGAGE or machining to true bore.
SCALE
Replace the crankshaft or grind to accept the ap
propriate undersize bearing inserts if:
• Journal diameters 1 through 6 are less than
63.4517 mm (2.4981 inches)
• Journal 7 diameter is less than 63.4365 mm
(2.4975 inches).
Once the proper clearances have been obtained,
proceed to Crankshaft Main Bearing—Installation.
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT
REMOVED)
Remove the crankshaft from the cylinder block (re
fer to Cylinder Block - Disassemble).
PLASTIGAGE Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
Fig, 5 Measuring Bearing Clearance with Plastigage with a micrometer. Measure at two locations 90°
Plastigage should indicate the same clearance apart at each end of the journal.
across the entire width of the insert. If clearance var The maximum allowable taper and out of round is
ies, it may indicate a tapered journal or foreign ma 0.013 mm (0.0005 inch). Compare the measured di
terial trapped behind the insert. ameter with the journal diameter specification (Main
If the specified clearance is indicated and there are Bearing Fitting Chart). Select inserts required to ob
no abnormal wear patterns, replacement of the bear tain the specified bearing-to-journal clearance.
ing inserts is not necessary. Remove the Plastigage Install the crankshaft into the cylinder block (refer
to Cylinder Block - Assemble and Crankshaft Main
from the crankshaft journal and bearing insert. Pro
Bearings - Installation).
ceed to Crankshaft Main Bearing—Installation.
If the clearance exceeds specification, install a pair INSTALLATION
of 0.025 mm (0.001 inch) undersize bearing inserts (1) Lubricate the bearing surface of each insert
and measure the clearance as described in the previ with engine oil.
ous steps. (2) Loosen all the main bearing caps. Install the
The clearance indicated with the 0.025 mm (0.001 main bearing upper inserts.
inch) undersize insert pair installed will determine if (3) Install the lower bearing inserts into the main
this insert size or some other combination will pro bearing caps.
vide the specified clearance. (4) Install the main bearing cap(s) and lower in
F O R E X A M P L E : If the clearance was 0.0762 mm serts).
(0.003 inch) originally, a pair of 0.0254 mm (0.001 (5) Tighten the bolts of caps 1, 2, 4, 5, 6, and 7 to
inch) undersize inserts would reduce the clearance by 54 N»m (40 ft. lbs.) torque. Now tighten these bolts to
0.0254 mm (0,001 inch). The clearance would then be 95 N»m (70 ft. lbs.) torque. Finally, tighten these
0.0508 mm (0.002 inch) and within the specification. bolts to 108 N*m (80 ft. lbs.) torque.
A 0.051 mm (0.002 inch) undersize bearing insert (6) Push the crankshaft forward and backward.
and a 0.0254 mm (0.001 inch) undersize insert would Load the crankshaft front or rear and tighten cap
reduce the original clearance an additional 0.0127 bolt No.3 to 54 N-m (40 ft. lbs.) torque. Then tighten
mm (0.0005 inch). The clearance would then be to 95 N«m (70 ft. lbs.) torque and finally tighten to
0.0381 mm (0.0015 inch). 108 N*m (80 ft. lbs.) torque.
(7) Rotate the crankshaft after tightening each
CAUTION: Never use a pair of inserts ..that differ main bearing cap to ensure the crankshaft rotates
more than one bearing size as a pair. freely.
(8) Check crankshaft end play. Crankshaft end
F O R E X A M P L E : Do not use a standard size up play is controlled by the thrust bearing which is
per insert and a 0.051 mm (0.002 inch) undersize flange and installed at the No.2 main bearing posi
lower insert. tion.
MAIN BEARING FITTING CHART
Crankshaft tearing I n s e r t Color Cod©

Color Code a n d D i a m e t e r
(Journal Size) Upper Insert Size Lower Insert Size
(2.5001-2.4996 in.)
Orange - 63.4898-63.4771 mm Yellow - Standard Blue - Undersize

(2.4996-2.4991 in.) 0.025 mm (0.001 in.)
Black - 63.4771-63.4644 mm Blue - Undersize Blue - Undersize

(2.4991-2.4986 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Green - 63.4644-63.4517 mm Blue - Undersize Green - Undersize

(2.4986-2.4981 in.) 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
Red - 63.2485-63.2358 mm Red - Undersize Red - Undersize

(2.4901-2.4966 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Crankshaft Main Bearing Journal 7 B e a r i n g I n s e r t C o l o r Code

C o l o r Code and D i a m e t e r
(Journal Size) Upper Insert Size L o w e r Insert Size

(2.499-2.4990 in.)
Orange - 63.4746-63.4619 mm Yellow - Standard Blue • Undersize

(2.4990-2.4985 in.) 0.025 mm (0.001 in.)
Black - 63.4619-63.4492 mm Blue - Undersize Blue - Undersize

(2.4985-2.4980 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Green - 63.4492-63.4365 mm Blue - Undersize Green - Undersize

(2.4980-2.4975 in.) 0.025 mm (0.001 in.) 0.051 mm (0.002 in.)
Red - 63.2333-63.2206 mm Red - Undersize Red - Undersize

(2.4895-2.4890 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
J9209-52
(a) Attach a magnetic base dial indicator to the REMOVAL
cylinder block at either the front or rear of the en (1) Remove the engine flywheel or converter drive
gine. plate.
(b) Position the dial indicator rod so that it is (2) Remove the oil pan.
parallel to the center line of the crankshaft. (3) Remove the rear main bearing cap (No.7).
(c) Pry the crankshaft forward, position the dial (4) Push the upper seal out of the groove. Ensure
indicator to zero. that the crankshaft and seal groove are not damaged.
(d) Pry the crankshaft forward and backward. (5) Remove the lower half of the seal from the
Note the dial indicator readings. End play is the bearing cap.
difference between the high and low measurements
(Fig. 6). Correct end play is 0.038-0.165 mm INSTALLATION
(0.0015-0.0065 inch). The desired specifications are (1) Wipe the seal surface area of the crankshaft
0.051-0.064 mm (0.002-0.0025 inch). until it is clean.
(2) Apply a thin coat of engine oil.
DIAL
INDICATOR
(3) Coat the lip of the seal with engine oil.
(4) Carefully position the upper seal into the
groove in the cylinder block. The lip of the seal faces
toward the front of the engine.
(5) Place the lower half of the seal into bearing cap
No.7 (Fig. 7).
(6) Coat the outer curved surface of the lower seal
with soap and the lip of the seal with engine oil (Fig.
7).
R E A R M A I N BEARING SEAL
J9009-1
CRANKSHAFT
Fig. 6 Crankshaft End Play Measurement

(e) If end play is not within specification, inspect BEARING
CAP
crankshaft thrust faces for wear. If no wear is ap
parent, replace the thrust bearing and measure end
play. If end play is still not within specification, re
place the crankshaft.
If the crankshaft was removed, install the crank
shaft into the cylinder block (refer to Cylinder Block
- Assemble).
(9) Install the oil pan.
(10) Install the drain plug. Tighten the plug to 41
N*m (30 ft. lbs.) torque.
BEARING
(12) Install the spark plugs. Tighten the plugs to CAP J8909-169
37 Nnn (27 ft. lbs.) torque.
(13) Fill the oil pan with engine oil to the full Fig. 7 Rear Main Bearing Oil Seal
mark on the dipstick level. (7) Position the lower seal into the bearing cap re
(14) Connect negative cable to battery. cess and seat it firmly. Be sure the seal is flush with
the cylinder block pan rail.
REAR MAIN OIL SEALS (8) Apply Loctite 515, or equivalent on the rear
The crankshaft rear main bearing oil seal consists bearing cap (Fig. 8). The bead should be 3 mm (0.125
of two half pieces of viton with a single |ip that ef in) thick. DO NOT apply Loctite 515, or equivalent
fectively seals the rear of the crankshaft. Replace the to the lip of the seal.
upper and lower seal halves as a unit to ensure leak-
(9) Install the rear main bearing cap. DO NOT
free operation.
strike the cap more than twice for proper engage
ment.
J 4.0L ENGINE S - 86
CLEANING
Thoroughly clean the oil pan and engine block gas
ket surfaces.
Use compressed air to clean out:
• The galley at the oil filter adaptor hole, the filter
bypass hole.
• The front and rear oil galley holes.
• The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Loctite PST pipe sealant with Teflon 592 to the
L O C T I T E 515 threads of the front and rear oil galley plugs.
(OR E Q U I V A L E N T ) Tighten the plugs to 41 N*m (30 ft. lbs.) torque.
INSPECTION-CYLINDER BORE
(1) Use a bore gauge to measure each cylinder bore
diameter (Fig. 9). If a bore gauge is not available,
use an inside micrometer.
Fig. 8 Location of Loctite 515 (or equivalent)

(10) Tighten all main bearing bolts to 108 N«m (80
ft. lbs.) torque.
(11) Install the oil pan gasket and oil pan.
(12) Install the engine flywheel or converter drive
plate.
CYLINDER BLOCK
Remove the Engine Assembly from the vehicle.
DISASSEMBLY
Refer to the applicable sections for detailed instruc
tions.
(1) Drain the engine oil. Remove and discard the
oil filter.
(2) Remove the water pump from the cylinder
J8909-134
block.
(3) Remove the vibration damper. Fig. 9 Cylinder Bore Measurement
(4) Remove the timing case cover and lay the cover
(2) Measure the cylinder bore diameter crosswise
upside down.
to the cylinder block near the top of the bore. Repeat
(5) Position a drift punch into the slot in the back
the measurement near the bottom of the bore.
of the cover and tap the old seal out.
(3) Determine taper by subtracting the smaller di
(6) Remove the oil slinger from crankshaft.
ameter from the larger diameter.
(7) Remove the camshaft retaining bolt and re
(4) Rotate measuring device 120° and repeat steps
move the sprockets and chain as an assembly.
above. Finally, rotate the device another 120° and re
(8) Remove the camshaft.
peat measurements.
(9) Remove the oil pan and gasket.
(5) Determine out-of-roundness by comparing the
(10) Remove the front and rear oil galley plugs.
difference between each 120° measurement.
(11) Remove the oil pump.
(6) If cylinder bore taper does not exceed 0.025 mm
(12) Remove the connecting rods and the pistons.
(0.001 inch) and out-of-roundness does not exceed
Remove the connecting rod and piston assemblies
0.025 mm (0.001 inch), the cylinder bore can be
honed. If the cylinder bore taper or out-of-round con
(13) Remove the crankshaft.
dition exceeds these maximum limits, the cylinder
must be bored and then honed to accept an oversize
9 - §8 4.0L ENGINE J
piston. A slight amount of taper always exists in the (3) Install the oil pump.
cylinder bore after the engine has been in use for a (4) Install the oil pan and gasket.
period of time. (5) Install the camshaft.
(6) Install the sprockets and chain as an assembly.
HONING—CYLINDER BORE (7) Install the oil slinger from the crankshaft.
The honing operation should be closely coordinated (8) Install the timing case cover seal.
with the fitting of pistons and rings. This will ensure (9) Install the timing case cover.
specified clearances are maintained. (10) Install the vibration damper.
Refer to Standard Service Procedures in the begin
(11) Install the water pump. Tighten the mounting
ning of this Group for the proper honing of cylinder
bolts to 34 N»m (25 ft. lbs.) torque.
bores.
(12) Lubricate the oil filter seal with clean engine
ASSEMBLY oil. Tighten oil filter to 18 N*m (13 ft. lbs.) torque.
Refer to the applicable sections for detailed instruc (13) Install the engine into the vehicle.
tions. (14) Fill the engine with clean lubrication oil (re
(1) Install the crankshaft. fer to Group 0, Lubrication and Maintenance).
(2) Install the connecting rods and the pistons (15) Fill the cooling system (refer to Group 7, Cool
through the top of the cylinder bores. ing System for the proper procedures).
4.0L ENGINE 9 - 87
SPECIFICATIONS
ENGINE SPECIFICATIONS
Camshaft Cylinder Block
Hydraulic Tappet Clearance ..Zero Lash Deck Height 239.49 - 239.64 mm

Bearing Clearance 0.025 - 0.076 mm (9.429 - 9.435 in)
(0.001 -0.003 in) Deck Clearance (Below Block) 0.546 mm
Bearing Journal Diameter (0.0215 in)
No.l .51.54 -51.56 mm Cylinder Bore Diameter
(2.029-2.030 in) Standard 98.42 - 98.48 mm
No.2.....................................................51.28-51.31 mm (3.8751 -3.8775 in)
{2.019-2.020 in) Taper (Max.) 0.025 mm
No.3 51.03-51.05 mm (0.001 in)
(2.009-2.010 in) Out-of-Round 0.025 mm
No.4....... 50.78 - 50.80 mm (0.001 in)
(1.999-2.000 in) Tappet Bore Diameter 23.000 - 23.025 mm
Base Circle Runout 0.03 mm - max. (0.9055 - 0.9065 in)
(0.001 in - max.) Flatness 0.03 mm per 25 mm
Camshaft Lobe Lift 6.43 mm (0.001 in per 1 in)
(0.253 in) 0.05 mm per 152 mm
Valve Lift. ....10.29 mm (0.002 in per 6 in)
(0.405 in) 0.20 mm - max. for total length
Intake Valve Timing (0.008 in - max. for total length)
Opens................. 15°BTDC Main Bearing Bore Dia ..68.3514- 68.3768 mm
Closes.......... ........75°ABDC (2.691 -2.692 in)
Exhaust Valve Timing
Opens ....59°BBDC Connecting Rods
Closes.... 31°ATDC
Valve Overlap .46° Total Weight (Less Bearing) 657 - 665 grams
Intake Duration .................270° (23.17- 23.45 oz)
Exhaust Duration 270° Length (Center-to-Center) 155.52 -155.62 mm
(6.123-6.127 in)
Crankshaft Piston Pin Bore Diameter 23.59 - 23.62 mm
(0.9288-0.9298 in)
End Play 0.038 - 0.165 mm Bore (Less Bearings) ..56.08 - 56.09 mm
(0.0015-0.0065 in) (2.2080-2.2085 in)
Main Bearing Journal Dia... 63.489 - 63.502 mm Bearing Clearance. ....0.025 - 0.076 mm
(2.4996-2.5001 in) Preferred 0.044 - 0.050 mm
Main Bearing Journal Width (0.001 -0.003 in)
No.l 27.58-27.89 mm Preferred....(0.0015 - 0.0020 in)
(1.086-1.098 in) Side Clearance. ....0.25 - 0.48 mm
No.3 ....32.28 - 32.33 mm (0.010-0.019 in)
(1.271 -1.273 in) Twist (Max.) 0.001 mm per mm
No.2-4-5-6-7............ 30.02 -30.18 mm (0.001 in per in)
(1.182- 1.188 in) Bend (Max.) 0.0005 mm per mm
Main Bearing Clearance .0.03 - 0.06 mm (0.0005 in per in)
Preferred 0.051 mm
(0.001 -0.0025 in) Cylinder Compression Pressure
Connecting Rod Journal Dia 53.17-53.23 mm Ratio 8.8:1
(2.0934-2.0955 in) Pressure Range 8 2 7 - 1 034 kPa
Connecting Rod Journal Width 27.18 - 27.33 mm (120-150 psi)
(1.070-1.076 in) Max. Variation Between Cylinders 206 kPa
Out-of-Round (Max. All Journals) ...0.013 mm (30 psi)
(0.0005 in)
Taper (Max. - All Journals) ....0.013 mm
(0.0005 in)
J9209-26
I - 88 4.0L ENGINE
ENGINE SPECIFICATIONS (CONTJ
Cylinder Head Valve Springs
Combustion Chamber ........................64.45 - 67.45 cc Free Length (Approx.) 46.22 mm

(3.93-4.12 cu. in.) (1.82 in)
Valve Guide I.D. (Integral) 7.9 mm Spring Tension
(0.312 in) Valve Closed 293 - 329 N @ 41.275 mm
Valve Stem-to-Guide Clearance 0.025 - 0.076 mm ( 6 6 - 7 4 l b f @ 1.625 in)
(0.001 -0.003 in) Valve Open ...911 - 978 N @ 30.48 mm
Intake Valve Seat Angle 44.5° (205 - 220 Ibf @ 1.20 in)
Exhaust Valve Seat Angle .44.5° Inside Diameter 24.08 - 24.59 mm
Valve Seat Width 1.02 -1.52 mm (0.948-0.968 in)
(0.040-0.060 in)
Valve Seat Runout 0.064 mm Pistons
(0.0025 in)
Flatness 0.03 mm per 25 mm Weight (Less Pin) 563 - 567 grams
(0.001 in per 1 in) (19.86-20.00 oz)
0.05 mm per 152 mm Piston Pin Bore (Centerline-to-Piston Top) 40.61 - 40.72 mm
(0.002 in per 6 in) 1.599-1.603 in)
0.20 mm - max. for total length Piston-to-Bore Clearance 0.033 - 0.053 mm
(0.008 in - max. for total length) Preferred........0.033 -0.038 mm
(0.0013-0.0021 in)
Rocker Arms, Push Rods & Tappets Preferred.....(0.0013 - 0.0015 in)
Piston Ring Gap Clearance
Rocker Arm Ratio 1.6:1 Compression Rings 0.25 - 0.51 mm
Push Rod Length 244.856 - 245.364 mm (0.010-0.020 in)
(9.640-9.660 in) Oil Control Steel Rails 0.25 - 0.64 mm
Push Rod Diameter. 7.92 - 8.00 mm (0.010-0.025 in)
(0.312-0.315 in) Piston Ring Side Clearance
Hydraulic Tappet Diameter ..22.962 - 22.974 mm Compression Rings 0.025 - 0.081 mm
(0.904 - 0.9045 in) Preferred 0.025 mm
Tappet-to-Bore Clearance.... 0.025 - 0.063 mm (0.001 -0.0032 in)
(0.001 - 0.0025 in) Preferred... (0.001 in)
Oil Control Ring 0.025 - 0.241 mm
Volves Preferred 0.08 mm
(0.001 -0.0095 in)
Length (Tip-to-Gauge Dimension Line) Preferred (0.003 in)
Intake ..122.479-122.860 mm Piston Ring Groove Height
(4.822-4.837 in) Compression Rings 2.019- 2.045 mm
Exhaust................................ .122.860-123.241 mm (0.0795-0.0805 in)
(4.837-4.852 in) Oil Control Ring 4.78 - 4.80 mm
Valve Stem Diameter .7.899 - 7.925 mm (0.1880-0.1895 in)
(0.311 -0.312 in) Piston Ring Groove Diameter
Stem-to-Guide Clearance 0.025 - 0.076 mm Compression Rings 88.30 - 88.55 mm
(0.001-0.003 in) (3.476-3.486 in)
Valve Head Diameter Oil Control Ring ......90.35 - 90.60 mm
Intake 48.387 - 48.641 mm (3.557-3.566 in)
(1.905-1.915 in) Piston Pin Bore Diameter. 23.647 - 23.655 mm
Exhaust 37.973 - 38.227 mm (0.9310-0.9313 in)
(1.495-1.505 in) Piston Pin Diameter. 23.637 - 23.640 mm
Valve Face Angle (0.9306 - 0.9307 in)
Intake 45° Piston-to-Pin Clearance 0.0076 - 0.0178 mm - Loose
Exhaust 45° Preferred 0.013 mm
Tip Refinishing (Max. Allowable) 0.25 mm (0.0003 - 0.0007 in - Loose)
(0.010 in) Preferred.. (0.0005 in)
Piston-to-Pin Connecting Rod (Press Fit) ...8.9 kN
(2000 Ibf)
J920953
V
ENGINE SPECIFICATIONS (CONT.f
Oil Pump Oil Pressure
Gear-to-Body Clearance (Radial) ..0.051 -0.102 mm At Idle Speed (600 rpm) .........89.6 kPa
Preferred.... 0.051 mm (13 psi)
(0.002-0.004 in) At 1600 rpm & higher... ,255-517kPa
Preferred (0.002 in) (37-75 psi)
Gear End Clearance Oil Pressure Relief. 517kPa
Plastigage 0.051 -0.152 mm (75 psi)
Preferred... 0.051 mm
(0.002-0.006 in)
Feeler Gauge ...0.1016-0.2032 mm
Preferred.... 0.1778 mm
(0.004-0.008 in)
Preferred (0.007 in) J9209-28
A/C Compressor Bracket-to- Oil Filter 18 N-m (13 ft. lbs.;

Engine Bolts 34 N m (25 ft. lbs.) Oil Galley Plug 41 N-m (30 ft. lbs.;
A/C Compressor Mounting Oil Pan Bolts (1/4-20) 13 N-m (114 in. lbs.
Bolts . . . . . 27 N m (20 ft. lbs.) (5/16-18) 18 N-m (156 in. lbs.
A/C Low Pressure Service Oil Pan Drain Plug 41 N-m (30 ft. lbs.
Valve Nut 38 N m (28 ft. lbs.) Oil Pump Attaching Bolts
Camshaft Sprocket B o l t . . . . . . 108 N m (80 ft. lbs.) (Short Bolts) 14 N-m (10 ft. lbs.)
Connecting, Rod Nuts . . . . . . . 45 N m (33 ft. lbs.) (Long Bolts) 23 N-m (17 ft. lbs.)
Crossmember-to-Sill Bolts Oil Pan Cover Bolts 8 N-m (70 in. lbs.)
(XJ Vehicles) 41 N-m (30 ft. lbs.) Power Steering Pump Pressure
Cylinder Head Bolts Hose Nut 52 N-m (38ft.lbs.)
(#1-10 & #12-14) 149 N m (110 ft. lbs.) Rear Support Bracket-to-
(#11) 135 N m (100 ft. lbs.) Transmission Bolts (YJ) 56 N-m (41ft.lbs.)
Cylinder Head Cover Bolts . . . 9 N m (75 in. lbs.) Rear Support Bracket Stud Nuts
Engine Support Bracket Bolts . 61 N-m (45 fl. lbs.) (XJ-Manual Trans.) 46 N-m (34ft.lbs.)
Exhaust Manifold-to-Pipe Nuts 27 N m (20 ft. lbs.) Rear Support Bracket Stud Nuts
Flywheel/Converter Housing (XJ-Automatic Trans.) 75 N-m (55ft.lbs.)
Bolts 38 N-m (28 ft. lbs.) Rocker Arm Assembly-to-
Front Cover-to-Block Bolts . . . . 7 N-m (60 in. lbs.) Cylinder Head Capscrews . . . 28 N-m (21ft.lbs.)
Front Support Bracket-to- Skid Plate-to-Sill Bolts (YJ) 88 N-m (65ft.lbs.)
Cylinder Block Bolts 61 N-m (45 ft. lbs.) Spark Plugs 37 N-m (27ft.lbs.)
Front Support Cushion-to- Starting Motor Mounting
Mount Thru Bolt 65 N m (48 ft. lbs.) 45 N-m (33 ft. lbs.)
Bolts
Front Support Cushion-to- Timing Case Cover-to-
Sill Bracket (XJ) ....... 41 N-m (30 ft. lbs. Block Bolts . 7 N-m (60 in. lbs.)
(YJ) . . . . . . • 65 N-m (48 ft. lbs. Transmission Support Cushion
Fuel Pump Bolts 22 N-m (16 ft. lbs. Nuts(YJ) 56 N-m (41ft.lbs.)
Generator Adjusting Bolt 24 N-m (18 ft. lbs. Trans. Support Cushion/Torque
Generator Pivot Bolt/Nut 38 N-m (28 ft. lbs. 56 N-m (41ft.lbs.)
Arm Brocket Bolts (YJ)
Main Bearing Bolts 108 N-m (80ft. lbs.; Vibration Damper Bolts 108 N-m (80ft.lbs.)
J9309-34 Water Pump-to-Block Bolts 34 N-m (25 ft. lbs.)
J EXHAUST SYSTEM AND INTAKE MANIFOLD 1 1 - 1
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM 1 SERVICE PROCEDURES 3

EXHAUST SYSTEM DIAGNOSIS 2 TORQUE SPECIFICATIONS 10
EXHAUST SYSTEM
GENERAL INFORMATION tern contacts any body panel, it may amplify objec
The basic exhaust system consists of an engine ex tionable noises originating from the engine or body.
haust manifold, exhaust pipe with oxygen sensor, When inspecting an exhaust system, critically in
catalytic converter, exhaust heat shield(s), muffler spect for cracked or loose joints, stripped screw or
and exhaust tailpipe (Fig. 1 ) . bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to re
pair.
When replacement is required, use original equip
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
CAUTION: Avoid application of rust prevention

compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light overs-
pray near the edges i s permitted. Application of
coating will result in excessive floor pan tempera
tures and objectionable fumes.
EXHAUS]>^ I
CATALYTIC CONVERTER
PIPE^ ^ HEAT SHIELD The stainless steel catalytic converter body is de
(BOTTOM)
signed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces
sive heat will not be the fault of the converter. If un-
burned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid contami
Fig. 1 Typical Exhaust System nating the catalyst core.
The exhaust system uses a single muffler with a
single monolithic-type catalytic converter. EXHAUST HEAT SHIELDS
The 4.0L engines use a seal between the engine ex Exhaust heat shields are needed to protect both the
haust manifold and exhaust pipe to assure a tight vehicle and the environment from the high tempera
seal and strain free connections. tures developed by the catalytic converter. The cata
The exhaust system must be properly aligned to lytic converter releases additional heat into the
prevent stress, leakage and body contact. If the sys- exhaust system. Under severe operating conditions,
the temperature increases in the area of the con-
11-2 EXHAUST SYSTEM AND INTAKE MANIFOLD J
verter. Such conditions can exist when the engine increase caused by unburned fuel passing through
misfires or otherwise does not operate at peak effi the converter.
ciency. DO NOT allow the engine to operate at fast idle for
DO NOT remove spark plug wires from plugs or by extended periods (over 5 minutes). This condition
any other means short out cylinders. Failure of the may result in excessive temperatures in the exhaust
catalytic converter can occur due to a temperature system and on the floor pan.
EXHAUST SYSTEM DIAGNOSIS
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. B u r n e d o r blown-out muffler. 2. Replace muffler assembly. Check

exhaust system.
3. B u r n e d o r rusted-out exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold flange. 4. Tighten connection attaching nuts.
5. Exhaust manifold cracked o r broken. 5. Replace exhaust manifold.
6. Leak between exhaust manifold and 6. Tighten exhaust manifold to cylinder

cylinder head. head stud nuts o r bolts.
7. Restriction in muffler o r tail pipe. 7. Remove restriction, i f possible. Replace

muffler o r tail pipe, as necessary.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Damaged o r improperly installed gaskets. 2. Replace gaskets, as necessary.
E N G I N E H A R D T O W A R M UP 1. Blocked crossover passage in intake 1. Remove restriction o r replace intake

OR WILL NOT RETURN T O manifold. manifold.
N O R M A L IDLE 2. Thermostat broken. 2. Replace thermostat.
J9311-13
J EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
8 E R W 1 C E PROCEDURES
INDEX
page page
Catalytic Converter ........................ 4 Intake Manifold—2.5L Engine ................ 7
Engine Exhaust Manifold—2.5L Engine . . . . . . . . . 7 Intake Manifold—4.0L Engine ................ 8
Engine Exhaust Manifold—4.0L Engine . . . . . . . . . 7 Muffler and Exhaust Tailpipe—XJ Vehicles ...... 5
Exhaust Pipe—XJ Vehicles 3 Muffler and Exhaust Tailpipe—YJ Vehicles ...... 6
Exhaust Pipe—YJ Vehicles . . . . . . . . . . . . . . . . . . 4
EXHAUST P I P E - X J VEHICLES
WARNING: IF TORCHES ARE USED W H E N W O R K

ING ON THE EXHAUST SYSTEM, DO N O T A L L O W
THE FLAME NEAR THE FUEL-LINES.
REMOVAL
(2) Saturate the bolts and nuts with heat valve lu
bricant (Fig. 1). Allow 5 minutes for penetration.
Fig. 2 Oxygen (OJ Sensor

(6) Disconnect the exhaust pipe from the catalytic
converter flange and support (Fig. 3). Discard the
gasket. Remove the exhaust pipe.
Fig. 1 Exhaust Pipe-to-Engine Exhaust Manifold

Nuts
(3) Remove the Oxygen (0 ) Sensor from the ex
2
haust pipe (Fig. 2).

(4) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal (4.0L engine,
only).
(5) Support the transmission and remove the rear
crossmember.
Fig. 3 Exhaust Pipe-to-Catalytlc Converter
Connection—XJ Vehicles
INSTALLA HON (5) Disconnect the exhaust pipe from the catalytic
(1) Use a replacement gasket and connect the ex converter flange and support (Fig. 5). Note the bolt
haust pipe to the catalytic converter flange and sup locations. Discard the gasket. Remove the exhaust
port (Fig. 3). Tighten the nuts to 34 N-m (25 ft. lbs.) pipe.
torque.
(2) Connect the exhaust pipe to the engine exhaust
manifold. Install a new seal between the exhaust
manifold and the pipe (4.0L engine, only). Tighten
the nuts to 31 Nun (23 ft. lbs.) torque (Fig. 1).
(3) Install the rear crossmember. Tighten the
#
crossmember-to-sill bolts to 41 N m (30 ft. lbs.)
torque. Remove the support from the transmission.
(4) Coat the Oxygen ( 0 ) Sensor with anti-seize
2
compound. Install the sensor and tighten the nut to

EXHAUST PIPE—YJ VEHICLES
W A R N I N G : IF T O R C H E S A R E U S E D W H E N W O R K
ING O N T H E E X H A U S T S Y S T E M , D O N O T A L L O W
THE F L A M E N E A R T H E F U E L L I N E S .
REMOVAL J8911-25
(2) Saturate the bolts and nuts with heat valve lu Fig. 5 Exhaust Pipe-to-Catalytic Converter
bricant (Fig. 4). Allow 5 minutes for penetration. Connection—YJ Vehicles
INSTALLATION
(1) Use a replacement gasket and connect the ex
haust pipe to the catalytic converter flange and sup
port (Fig. 5). Install the bolts and nuts in the same
location as removed. Do not tighten the nuts.
(2) Clean the mating surface of the engine exhaust
manifold flange.
(3) Connect the exhaust pipe to the engine exhaust
manifold using new nuts. Do not tighten the nuts.
(4) Align the exhaust pipe.
(5) Tighten the nuts at the catalytic converter and
exhaust pipe support area to 34 N»m (25 ft. lbs.)
torque.
(6) Tighten the exhaust pipe-to-engine exhaust
manifold nuts to 31 N*m (23 ft. lbs.) torque.
(7) Coat the Oxygen ( 0 ) Sensor wi|;h anti-seize
2
compound. Install the sensor and tighten the nut to

J8911-23 CATALYTIC CONVERTER
Fig. 4 Exhaust Pipe-to-Engine Exhaust Manifold WARNING: IF TORCHES ARE USED WHEN WORK
Bolts and Nuts ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(3) Remove the Oxygen ( 0 ) Sensor from the ex
2
haust pipe (Fig. 2).

(4) Disconnect the exhaust pipe from the engine REMOVAL
exhaust manifold. (1) Raise and support the vehicle.
(2) Remove the clamp from the catalytic converter
J EXHAUST S Y S T E M AND INTAKE MANIFOLD 11 - 5
(3) Remove the rear exhaust tailpipe hanger clamp

(Fig. 7) and remove the exhaust tailpipe from the
front exhaust tailpipe hanger (Fig. 8).
Fig. 6 Catalytic Converter-to-Muffler Connection

and muffler connection (Fig. 6).
(3) Heat the catalytic converter and muffler con
nection with an oxyacetylene torch until the metal Fig. 7 Rear Exhaust Tailpipe Hanger Clamp
becomes cherry red.
(4) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(5) Disconnect the exhaust pipe from the catalytic
converter flange and support (Figs. 3 and 5). Discard
the gasket.
INSTALLATION
(1) Use a replacement gasket and connect the cat
alytic converter flange to the exhaust pipe flange
(Figs. 3 and 5). Tighten the nuts to 34 N i n (25 ft.
lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align
ment slot.
(3) Install a clamp at the muffler and catalytic
converter connection (Fig. 6). Tighten the clamp nuts
to 61 N*m (45 ft. lbs.) torque.
M U F F L E R AND E X H A U S T T A I L P I P E — X J V E H I C L E S
All original equipment exhaust systems are manu Fig. 8 Front Exhaust Tailpipe Hanger
factured with the exhaust tailpipe welded to a (4) Heat the catalytic converter-to-muffler connec
stamped muffler. Service replacement mufflers and tion with an oxyacetylene torch until the metal be
exhaust tailpipes are either clamped together or comes cherry red.
welded together. (5) While the metal is still cherry red, remove the
exhaust tailpipe/muffler assembly from the catalytic
WARNING: I F T O R C H E S A R E U S E D W H E N W O R K
converter.
ING ON T H E E X H A U S T S Y S T E M , DO NOT A L L O W
(6) Remove the exhaust tailpipe from the muffler:
T H E FLAME NEAR T H E F U E L LINES.
• To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
REMOVAL the muffler. Collapse the part remaining in the muf
(1) Raise and support the vehicle. fler and remove.
(2) Remove the front muffler clamp from the cata • To remove a service exhaust tailpipe/muffler com
lytic converter and muffler connection (Fig. 6). bination, apply heat until the metal becomes cherry
11-6 EXHAUST SYSTEM AND INTAKE MANIFOLD
red. Remove the exhaust tailpipe/muffler clamp and

J
twist the exhaust tailpipe out of the muffler.
INSTALLATION
( 1 ) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nuts finger tight.
( 2 ) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe hanger. Make sure that
the exhaust tailpipe has sufficient clearance from the
floor pan.
( 4 ) Install the remaining clamps and the front ex
haust tailpipe hanger.
( 5 ) Tighten the nuts on the muffler-to-catalytic
converter clamp to 6 1 N T H ( 4 5 ft. lbs.) torque (Fig.
6 ) . Tighten the nuts on the rear exhaust tailpipe
clamp to 1 4 N*m ( 1 0 ft. lbs.) torque (Fig. 7 ) .
( 6 ) Lower the vehicle.
( 7 ) Start the engine and inspect for exhaust leaks
J8911-26
and exhaust system contact with the body panels.
Adjust the alignment, if needed. Fig. 9 Rear Exhaust Tailpipe Hanger/Bracket
M U F F L E R AND EXHAUST TAILPIPE—YJ V E H I C L E S
.TAILPIPE
All original equipment exhaust systems are manu
factured with the exhaust tailpipe welded to the muf
fler. Service replacement mufflers and exhaust
tailpipes are clamped together.
WARNING: I F T O R C H E S A R E U S E D W H E N W O R K
ING ON T H E E X H A U S T S Y S T E M , DO NOT A L L O W
T H E FLAME NEAR T H E F U E L LINES.
REMOVAL
( 1 ) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
( 2 ) Remove the front muffler clamp from the cata
lytic converter and muffler connection (Fig. 6 ) .
(3) Remove the exhaust tailpipe hanger/bracket
(Fig. 9).
( 4 ) Remove the exhaust tailpipe from the front ex
haust tailpipe hanger (Fig. 1 0 ) . J8911-27
( 5 ) Heat the converter-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry Fig. 10 Front Exhaust Tailpipe Hanger
red.
( 6 ) While the metal is still cherry red, place a Heat the exhaust tailpipe-to-muffler connection with
block of wood against the front of the muffler and an oxyacetylene torch until the metal becomes cherry
drive the muffler rearward to disengage. red. While the metal is still cherry red, twist the ex
( 7 ) Remove the exhaust tailpipe/muffler assembly. haust tailpipe out of the muffler.
(8) Remove the exhaust tailpipe from the muffler:
• To remove an original equipment exhaust tailpipe/ INSTALLATION
muffler combination, cut the exhaust tailpipe close to ( 1 ) Install the muffler onto the catalytic converter
the muffler. Collapse the part remaining in the muf outlet. Ensure that the locator on the converter
fler and remove. aligns with the notch on the muffler, if so equipped.
• To remove a service exhaust tailpipe/muffler com Install the clamp and tighten the nuts finger tight.
bination, remove the exhaust tailpipe/muffler clamp.
J EXHAUST SYSTEM AND INTAKE MANIFOLD 11-7
(2) Install the exhaust tailpipe into the muffler (2) Install the engine exhaust manifold assembly.
outlet. Ensure that the locator on the exhaust Exhaust manifold must be centrally located over
tailpipe aligns with the notch on the muffler, if so the end studs and spacer (Fig. 11).
equipped. Install the clamp and tighten the nuts fin (3) Tighten bolt No.l to 41 N-m (30 ft. lbs.) torque
ger tight. (Fig. 11).
(3) Install the front exhaust tailpipe supports and (4) Install the intake manifold on the cylinder
the rear exhaust tailpipe hanger. Ensure that the ex head dowels (Fig. 11).
haust tailpipe has sufficient clearance from the floor (5) Install bolts 2 through 5 (Fig. 11). Tighten
pan and shields. these bolts to 31 N-m (23 ft. lbs.) torque.
(4) Tighten the nuts on the muffler-to-catalytic (6) Install new engine exhaust manifold spacers
converter and the muffler-to-exhaust tailpipe clamps over the engine exhaust manifold mounting studs in
to 61 N-m (45 ft. lbs.) torque. the cylinder head (Fig. 11).
(5) Lower the vehicle. (7) Tighten nuts 6 and 7 to 31 N-m (23 ft. lbs.)
(6) Start the engine and inspect for exhaust leaks torque (Fig. 11).
and contact with the body panels and shields. (8) Install all components to the intake manifold.
ENGINE EXHAUST MANIF0LD-2.iL ENGINE (10) Connect the exhaust pipe to the engine ex
haust manifold. Tighten the bolts to 31 N-m (23 ft.
REMOVAL lbs.) torque.
(1) Disconnect the battery negative cable. (11) Lower the vehicle.
(2) Remove all components attached to the intake (12) Connect the battery negative cable.
manifold. (13) Start the engine and check for leaks.
(4) Disconnect the exhaust pipe from the engine ENGINE EXHAUST MANIFOLD-4.0L ENGINE
exhaust manifold. The intake and engine exhaust manifolds on the
(5) Lower the vehicle. 4.0L engine must be removed and installed together.
(6) Remove fasteners 2 through 5 and remove the The manifolds use a common gasket at the cylinder
intake manifold (Fig. 11). head.
(7) Remove fasteners 1, 6 and 7 and remove the Refer to Intake Manifold—4. OL Engine in this sec
engine exhaust manifold (Fig. 11). tion for the proper removal and installation proce
dures.
CYLINDER H E A D D O W E L S
INTAKE MANIFOLD—2.5L ENGINE

REMOVAL
(2) Remove the air inlet hose from the throttle
body and air cleaner.
(3) Loosen the accessory drive belt tension and re
move the belt from the power steering pump.
(4) Remove the power steering pump and brackets
from the water pump and intake manifold. Support
power steering pump and bracket with mechanics
wire attached to the radiator upper crossmember.
(5) Remove the fuel tank filler cap to relieve the
MANIFOLD J9211-5 fuel tank pressure.
(6) Install the fuel tank filler cap.
Fig. 11 Intake/Engine Exhaust Manifold Installation (7) Disconnect fuel supply and return tube from
(2.5L Engine) the fuel rail (refer to Group 14, Fuel System - Quick
CLEANING Connect Fittings).
Clean the intake and engine exhaust manifolds (8) Disconnect the accelerator cable from the throt
and cylinder head mating surfaces. DO NOT allow tle body and the holddown bracket.
foreign material to enter either the intake mani
fold or the ports in the cylinder head. CAUTION: When disconnecting the cruise control
connector at the throttle body, do not pry the con
INSTALLATION nector off with pliers or screwdriver. U s e finger
(1) Install a new intake manifold gasket over the pressure only. Prying the connector off could break
alignment dowels on the cylinder head. it.
(9) Disconnect the electrical connectors. Pull the • Fastener No.l-Tighten to 41 N*m (30 ft. lbs.)
harnesses away from the manifold. torque.
• The throttle position sensor. • Fasteners Nos.2 through 7-Tighten to 31 N-m (23
• The idle speed control motor. ft. lbs.) torque.
• The coolant temperature sensor at the thermostat. (4) Connect the fuel return and supply tube to the
• The manifold air temperature sensor at the intake connector next to the fuel rail. Push them into the
manifold. fitting until a click is heard. Verify that the connec
• The fuel injectors. tions are complete.
• The oxygen ( 0 ) sensor.
2 • First, ensure only the retainer tabs protrude from
(10) Disconnect the crankcase ventilation (CCV) the connectors.
vacuum hose and manifold absolute pressure (MAP) • Second, pull out on the fuel tubes to ensure they
sensor vacuum hose connector at the intake mani are locked in place.
fold. (5) Connect the molded vacuum hoses to the vac
(11) Disconnect vacuum hose from vacuum port on uum port on the intake manifold and the cylinder
the intake manifold. head cover.
(12) Disconnect CCV hose at the cylinder head (6) Connect the electrical connectors.
cover (Fig. 12). • The throttle position sensor.
• The automatic idle speed control motor.
• The coolant temperature sensor at the thermostat
housing.
• The fuel injectors.
• The air manifold temperature sensor.
• The oxygen ( 0 ) sensor.
2
(7) Connect the CCV vacuum hose and MAP sen

sor vacuum hose connectors to the throttle body.
(8) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
(9) Connect the accelerator cable and cruise control
cable to the holddown bracket and the throttle arm.
CAUTION: Ensure that the accessory drive belt i s

routed correctly. Failure to do s o can cause the wa
ter pump to turn in the opposite direction resulting
Fig. 12 Crankcase Ventilation (CCV) Hose (2.5L in engine overheating. Refer to Group 7, Cooling
Engine) System for the proper procedure.
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at (10) Tension the accessory drive belt. Refer to
the intake manifold. Group 7, Cooling System for the proper procedure.
(15) Remove bolts 2 through 5 securing the intake (11) Connect the air inlet hose to the throttle body
manifold to the cylinder head (Fig. 11). Slightly and the air cleaner.
loosen bolt No.l and nuts 6 and 7. (12) Connect the battery negative cable.
(16) Remove the intake manifold and gaskets. (13) Start the engine and check for leaks.
Drain the coolant from the manifold.
INTAKE M A N I F O L D — 4 J L ENGINE
CLEANING The intake and engine exhaust manifolds on the
Clean the intake manifold and cylinder head mat 4.0L engine must be removed and installed together.
ing surfaces. DO NOT allow foreign material to The two manifolds use a common gasket at the cyl
enter either the intake manifold or the ports in inder head.
the cylinder head.
REMOVAL
INSTALLATION (1) Disconnect the battery negative cable.
(1) Install the new intake manifold gasket over the (2) Remove air cleaner inlet hose from throttle
locating dowels. plate assembly.
(2) Position the manifold in place and finger (3) Remove the air cleaner assembly.
tighten the mounting bolts. (4) Remove the throttle cable, cruise control cable
(3) Tighten the fasteners in sequence and to the (if equipped) and the transmission line pressure ca
specified torque (Fig. 11). ble.
j ^ . — EXHAUST SYSTEM AND INTAKE MANIFOLD 11-8
(5) Disconnect all electrical connectors on the in

take manifold.
(6) Disconnect and remove the fuel supply and re
turn lines from the fuel rail assembly (refer to Group
14, Fuel System).
(7) Loosen the accessory drive belt (refer to Group
7, Cooling System). Loosen the tensioner.
(8) Remove the power steering pump and bracket CYLINDER
from the intake manifold and set aside. HEAD DOWEL
(9) Remove the fuel rail and injectors (refer to
Group 14, Fuel System).
(10) Raise the vehicle. BOLT T O R Q U E
(11) Disconnect the exhaust pipe from the engine ® - ® 3 3 N m (24 f t . lbs.)
exhaust manifold. Discard the seal. ® - ® 23 N m (17 f t . lbs.)
EXHAUST
® - ® 3 3 N m ( 2 4 f t . lbs.)
(12) Lower the vehicle. MANIFOLD J9211-2
(13) Remove the intake manifold and engine ex
haust manifold. Fig. 13 Intake/Engine Exhaust Manifold Installation
(4.0L Engine)
CLEANING (8) Install the power steering pump and bracket to
Clean the mating surfaces of the cylinder head and the intake manifold. Tighten the belt to specification.
the manifold if the original manifold is to be in Refer to Group 7, Cooling System for the proper pro
stalled. cedures.
If the manifold is being replaced, ensure all the fit (9) Install the fuel supply and return lines to the
ting, etc. are transferred to the replacement mani
fuel rail assembly. Before connecting the fuel
fold.
lines to the fuel rail replace the O-rings in the
INSTALLATION quick-connect fuel line couplings. Refer to Group
(1) Install a new exhaust/intake manifold gasket 14, Fuel System for the proper procedure.
over the alignment dowels on the cylinder head. (10) Connect all electrical connections on the in
(2) Position the engine exhaust manifold to the take manifold.
cylinder head. Install fastener No.3 and finger (11) Connect the vacuum connector on the intake
tighten at this time (Fig. 13). manifold and install it in the bracket.
(3) Install intake manifold on the cylinder head (12) Install throttle cable, cruise control cable (if
dowels. equipped).
(4) Install washers and fasteners Nos.l, 2, 4, 5, 8, (13) Install the transmission line pressure cable (if
9, 10 and 11 (Fig. 13). equipped). Refer to Group 21, Transmission for the
(5) Install washers and fasteners Nos.6 and 7 (Fig. adjustment procedures.
13). (14) Install air cleaner assembly.
(6) Tighten the fasteners in sequence and to the (15) Connect air inlet hose to the throttle plate as
specified torque (Fig. 13). sembly.
• Fasteners Nos.l through 5—Tighten to 33 N-m (24 (16) Raise the vehicle on a side mounted hoist.
ft. lbs.) torque. (17) Using a new seal, connect the exhaust pipe to
• Fasteners Nos.6 and 7-Tighten to 23 N-m (17 ft. the engine exhaust manifold. Tighten the bolts to 31
lbs.) torque. N-m (23 ft. lbs.) torque.
• Fasteners Nos.8 through 11—Tighten to 33 N-m (18) Lower the vehicle.
(24 ft. lbs.) torque. (19) Connect the battery negative cable.
(7) Install the fuel rail and injectors. (20) Start the engine and check for leaks.
11-10 E X H A U S T S Y S T E M AND I N T A K E M A N I F O L D
Description Torqu® Description Torque
Catalytic Converter/Exhaust Exhaust Manifold N u t s #6 & 7

Pipe Flange N u t s 34 N-m (25 f t . lbs.) 2.5L Engine 31 N-m (23 f t . lbs.)
Crossmember-to-Sill Bolts . 41 N-m (30 f t . lbs.) Exhaust Manifold N u t s #6 & 7
Exhaust Pipe-to-Manifold 4.0L Engine . . . . . . . . . . . . . . . . . . . . 23 N-m (17 f t . lbs.)
Nuts 31 N-m (23 f t . lbs.) Intake Manifold Bolt #1
Exhaust Manifold Bolt #1 2.5L Engine 41 N-m (30 f t . lbs.)
2.5L Engine 41 N-m (30 f t . lbs.) Intake Manifold Bolts #2-5
Exhaust Manifold Bolts #2-5 2.5L Engine 31 N-m (23 f t . lbs.)
2.5L Engine 31 N-m (23 f t . lbs.) Muffler-to-Cata lytic
Exhaust/Intake Manifold N u t / Converter Clamp N u t s 61 N-m (45 f t . lbs.)
Bolts #1-5 & #8-11 Oxygen ( 0 ) Sensor
2 48 N-m (35 f t . lbs.)
4.0L Engine 33 N-m (24 f t . lbs.) Rear Tail Pipe Clamp N u t s . . . . . . . . . . 14 N-m (10 f t . lbs.)
J9211-1
J F R A M E AND B U M P E R S 13- 1
FRAME AND BUMPERS
CONTENTS
page page
XJ B U M P E R S 3 Y J B U M P E R S AND F R A M E ATTACHED
XJ UNIBODY CONSTRUCTION 1 COMPONENTS 14
YJ FRAME 8
XJ UNIBODY CONSTRUCTION
INDEX
page page
Collision Damage 1 General Information 1
GENERAL INFORMATION (1) Damage at the immediate point of impact—pri

Jeep® XJ Vehicles (Fig. 1) and the cab section of mary damage.
Jeep® are constructed as a unitized body and frame. (2) The other (lessor) body damage—secondary
damage.
(3) Damage to the exterior trim and other surface-
attached components.
(4) Damage to the mechanical components.
(5) The interior trim and accessory damage.
DAMAGE REPAIR
A logical approach to the sequence of damage re
pair must also be used. Usually, during vehicle re
pair, the tasks are accomplished in the reverse order
of consequence.
When there is damage to a vehicle, the alignment
points must be returned too specifications. This en
tails:
J91IN-12 • accurate measurement;
• repetitive measurement; and
Fig. 1Jeep®XJ • re-check of measurements.
Jeep® XJ unibodies are constructed from special Collision damage repair can be completed "right"
high-strength steel and coated metals. These types of the first time:
metals reduce weight and provide strength. • if the fundamental steps for collision damage re
pair are correctly followed, and
COLLISION DAMAGE • if the basic structural details of unibody construc
tion are correctly considered.
DAMAGE DIAGNOSIS
A vehicle constructed as a unibody reacts differ
ently to the impact of a collision. While the damage
at the immediate point of impact is easily recogniz
able, the damage must be diagnosed to expose it.
With unibody construction, there are five logical
areas to examine to expose damage.
Fig. 2 Frame Alignment Reference Dimensions—XJ Vehicles
FRAME AND BUMPERS 13 - 3
J
XJ BUMPERS
INDEX
page page
Front Bumper 3 Rear Bumper—XJ Vehicles 6
Front Tow Hooks ......................... 5
FRONT BUMPER VACUUM
REMOVAL/DISASSEMBLY
(1) The bumper guards, end caps and tow hooks
can be removed from XJ front bumpers with the
bumper attached to the vehicle. Do not remove the
bumper from the vehicle if only these components re
quire service.
If equipped with a brush guard, refer to the
Brush Guard Removal within Group 23—Body
Components.
(2) If equipped, disconnect the fog lamp wire har
ness connectors (Fig. 1).
FOG WIRE
J9223-53
Fig. 1 Fog Lamp Wire Harness Connector

(3) Disconnect the vacuum reservoir tube harness
connectors (Figs. 2 and 3 ) .
(4) If equipped, remove the locknuts and Torx-head
bolts that attach the tow hook straps (Fig. 4 ) to the
underbody sillmember.
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 Fig. 3 Vacuum Reservoir—Right Side With Speed
ber. Control Only
(6) Support the bumper.
(7) Remove the bolts that attach the bumper sup
port brackets to the right and left sillmembers (Fig.
5).
(8) Remove the support and the bumper from the
vehicle. 5 ) .
13 - 4 FRAME AND BUMPERS J
TORX-HEAD SCREW BUMPER TORX-HEAD TORX-HEAD BUMPER BUMPER

BOLT 1 S U P P O R T BRACKET BOLT BOLT BRACKET SUPPORT
(W/O T O W HOOK) BRACKET
( W / T O W HOOK)
BOLT
RIGHT SIDE
NUT
GUARD
I LOCK N U T
LOCK
NUT
TORX BUMPER . m — m . s
HEAD U-NUT RAIL WASHER ^^WASHER J°223-55

BOLT
Fig. 6 Bumper Support Bracket Removal/Installation
U-NUT
BUMPER
BUMPER TOW TORX-HEAD UNDERBODY BRACKET
HOOK BOLT SILL J9223-50
RAIL
Fig. 4 Tow Hook & Strap—XJ Vehicles NUT©
BUMPER TORX-HEAD U N D E R B O D Y SILL

BRACKET BOLT CROSSMEMBER BUMPER
(W/O T O W HOOK) RAIL
PLUG
(W/O GUARD)
BUMPER
GUARD
J9223-S6
Fig. 7 Bumper Guard Removal/Installation

REINFORCEMENT
SUPPORT BOLT
BRACKET
BRACKET
BUMPER
SUPPORT
BRACKET
( W / T O W HOOK) NUT
E N D CAP
BUMPER TORX-HEAD FRONT

GUARD BOLT BUMPER J9223-49
Fig. 5 Front Bumper Removal/Installation

(9) If equipped, remove the nuts and bolts that at
tach the tow hooks to the bumper support brackets.
BUMPER
(10) Remove the support brackets (Fig. 6), bumper RAIL PUSH N U T J9223-51
guards (Fig. 7) and caps (Fig. 8) from the bumper
rail. Fig. 8 Bumper End Cap Removal/Installation
(11) Remove the license plate bracket (Fig. 9), if
(13) If necessary, remove the vacuum reservoir(s)
equipped, from the bumper rail.
from the bumper rail.
(12) If equipped, remove the fog lamps (Fig. 10)
(14) If necessary, remove the sill crossmember re
from the bumper rail.
inforcement brackets from the sillmembers.
J FRAME AND BUMPERS 13 - 5
(2) If equipped, install the bumper support brack

ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in Figure 7.
Tighten the locknuts with 20 N-m (15 ft-lbs) torque.
Tighten bolts with 56 N-m (41 ft-lbs) torque.
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts with 56 N-m (41 ft-lbs) torque.
(4) If equipped with tow hooks, install the bolts
and nuts that attach them to the bumper support
brackets. Tighten nuts with 100 N-m (74 ft-lbs)
torque.
(5) Install the bumper end caps on the bumper rail
(Fig. 8). Tighten nuts with 8 N-m (72 in-lbs) torque.
(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
Fig. 9 Bumper License Plate Bracket Removal/ (7) If equipped, install the fog lamps on the
Installation bumper rail. Tighten the nuts securely.
(8) If removed, install the vacuum reservoir(s) on
PLUG
the bumper rail. Tighten the retaining screws and
bolts with 8 N-m (72 in-lbs) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack
ets. Tighten screws and bolts with 56 N-m (41 ft-lbs)
torque.
(11) If equipped, install the Torx-head bolts and
locknuts that attach the tow hook straps to the un
derbody sillmember. Tighten locknuts with 30 N-m
(22 ft-lbs) torque.
Install the steering gear skid plate and screws
J9123-421 after the left tow hook strap has been installed.
(12) If equipped, connect the fog lamp wire harness
Fig. 10 Fog Lamp connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
FRONT TOW HOOKS

If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 N-m (74 ft-lbs)
torque.
If a tow hook/bumper support bracket must be re
placed, refer to the following removal and installa
tion procedures.
REMOVAL
If equipped with a brush guard, refer to the
Brush Guard Removal within Group 23—Body
Fig. 11 Reinforcement Brackets Components.
ASSEMBLY/INSTALLATION (1) If equipped, disconnect the fog lamp wire har
(1) If removed, install the sill crossmember rein ness connectors.
forcement brackets on the sillmembers (Fig. 11). (2) Disconnect the vacuum reservoir tube harness
Tighten bolts with 56 N-m (41 ft-lbs) torque. connectors.
(3) Support the bumper.
13 - i FRAME AND iUMPERS
(4) Remove the bolts that attach the bumper sup (4) Remove the bolts that attach the bumper sup
port brackets to the right and left sillmembers. port brackets to the sill crossmember (Fig. 12).
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem
ber.
The retaining screws and the steering gear
skid plate must be removed before the left strap
can be removed from the sillmember.
(6) Detach the tow hook straps from the sillmem
ber.
(7) Remove the support and the bumper from the
vehicle.
(8) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(9) Remove the tow hook from the bumper support
bracket (Fig. 4).
(10) Remove the support bracket from the bumper J9223-57
rail.
Fig. 12 Rear Bumper Removal/Installation—XJ
INSTALLATION Vehicles
(1) If equipped, install the bumper guard and
bumper support bracket on the bumper rail. Tighten (5) Remove the support and the rear bumper from
the retaining hardware in the sequence indicated in the vehicle.
Figure 7. Tighten locknuts with 20 N-m (15 ft-lbs) (6) Remove the bumper support brackets and
torque. Tighten bolts with 56 N-m (41 ft-lbs) torque. splash shield the bumper, if necessary (Fig. 13).
(2) If not equipped with bumper guards, install the
bumper support bracket on the bumper rail. Tighten
bolts with 56 N-m (41 ft-lbs) torque.
(3) Position the tow hook at the support bracket.
Install the bolts and nuts that attach tow hook to the
bumper support bracket. (Fig. 4). Tighten nuts with
100 N-m (74 ft-lbs) torque.
(4) Position and support the bumper at the front of
the vehicle.
(5) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack
ets. Tighten screws and bolts with 56 N-m (41 ft-lbs)
torque,
(6) If equipped, install the Torx-head bolts and
locknuts that attach the tow hook straps to the un
derbody sillmember. Tighten locknuts with 30 N-m
(22 ft-lbs) torque. Fig. 13 Bumper Bracket & Splash Shield Removal/
Install the steering gear skid plate and screws Installation—XJ Vehicles
after the left tow hook strap has been installed.
(7) If equipped, connect the fog lamp wire harness (7) Remove the bumper end caps (Fig. 14) and
connectors. Connect the vacuum reservoir tube har bumper guards from the bumper (Fig. 15), if neces
ness connectors. sary.
(8) Remove the bumper support.
INSTALLATION
REAR i U M P E R - X J VEHICLES (1) As applicable, install the splash shield and
bumper support brackets, the bumper end caps and
REMOVAL the bumper guards.
(1) For vehicles equipped with a trailer hitch, re (2) Tighten the bumper support bolts with 56 N-m
move the hitch before removing the bumper. If nec (41 ft-lbs).
essary, refer to the removal procedure within Group (3) Tighten the nuts in the sequence depicted in
23—Body Components. Figure 14. Tighten the bumper end cap plate bolt
(2) Raise and support the rear of the vehicle. nuts with 22 N-m (16 ft-lbs) torque. Tighten the
(3) Support the bumper. lower bolt nuts with 8 N-m (6 ft-lbs) torque.
(EXTENSION) (EXTENSION) J9223-59
Fig. 14 Bumper End Cap Removal/Installation—XJ

Vehicles
(4) If applicable, tighten the bumper guard bolts/
nuts with 56 N-m (41 ft-lbs).
(5) Position and support the bumper with the
bracket holes aligned with the sill crossmember Fig. 15 Bumper Guard Removal/Installation—XJ
holes. Install the bracket-to-crossmember bolts. Vehicles
Tighten the bolts with 42 N T H (31 ft-lbs) torque. (6) If removed, install the trailer hitch. If neces
sary, refer to the installation procedure within Group
23—Body Components.
13 - 8 FRAME AND BUMPERS
YJFRAME
INDEX
page page
Frame Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 10 Frame Repair Service 13
Frame Inspection/Measurements 10 General Information . . 8
GENERAL INFORMATION
FUNCTIONS
The Jeep® YJ (Fig. 1) frame is the structural cen
ter of the vehicle. In addition to supporting the body
and payload, the frame provides a station for the en
gine. The vehicle body is attached to the frame with
holddowns (Figs. 2 and 3).
J91IN-10
Fig. 1 Jeep® YJ
13 - 10 FRAME A I D 1UMPERS J
CONSTRUCTION (2) Transfer these reference points to the surface/

The frame is constructed of high-strength channel floor with a plumb bob. Paper sheets can be attached
steel siderails and crossmembers. The crossmembers to the surface below the reference points for better
join the siderails and retain them in alignment in re measurement accuracy.
lation to each other. This provides resistance to (3) Locate the reference points on the other frame
frame twists and strains. siderail and transfer them to the surface/floor with
the same procedure as above.
FRAME ALIGNMENT (4) Move the vehicle away and measure between
all the reference points diagonally from and parallel
INCORRECT ALIGNMENT to the siderails (Fig. 5). The measurements should
Incorrect frame alignment is usually a result of: not differ by more than 6 mm (1/4 in).
• collision impact, or (5) Measure the distance between the two front
• the vehicle being operated with excessive loads, or reference points and the distance between the two
• loads not positioned in a properly distributed man rear reference points. Divide each distance in half
ner on the vehicle. and indicate the two half-way points on the surface/
A mis-aligned frame will affect front axle and/or floor. Designate the front point as "1" and the rear
rear axle alignment. It can cause excessive wear and point as "2" (Fig. 5).
mechanical failures in the powertrain. Window glass (6) Place a chalk-line between points 1 and 2 and
cracks and door opening/closing problems. Vehicle "snap" the string.
performance can also be impaired. (7) Determine how close the center line is to the
REALIGNMENT diagonal intersection points A, B, C, D, E, and F in
With collision damage, it is important that the ex Figure 5.
istence of any frame alignment damage be deter (8) The reference marks on the surface/floor will
mined. If necessary, the frame should be correctly re provide an illustrated indication of the degree of
aligned. Refer to the reference dimensions listed on frame misalignment.
frame alignment dimension chart (Fig. 4). (9) A reference point transferred from one frame
siderail may be 3 mm (1/8 in) ahead or behind the
FRAME INSPECTION/MEASUREMENTS reference point from the opposite siderail.
(10) Frame bow to the side should not exceed 3
INSPECTION mm per 2,540 mm (1/8 inch per 100 inches) in
Before proceeding with measurements, inspect all length.
components for visible damage and other metal dam (11) The overall width of the frame should not
age. Also, inspect all connections for loose and miss vary more than 3 mm (1/8 in) from reference point-
ing hardware. to-reference point.
All damaged areas must be repaired and/or the (12) Repeat steps (1) through (11) after straighten
components replaced, as necessary. ing the frame to evaluate the effectiveness.
MEASUREMENTS TWIST AND PARALLEL FRAME MEASUREMENTS

Measure the frame for mis-alignment with the Determine the amount of frame twist and siderail
body attached to the frame. Figure 4 provides the deviation according to the following procedure.
alignment reference dimensions. The following infor (1) Mark the vertical measurement reference
mation applies to all measurements. points under the frame siderails at 305-mm (12-in)
(1) Place the vehicle on a level surface. intervals starting at the rear frame crossmember.
(2) If the vehicle is loaded, ensure that the vehicle (2) Measure the vertical distance up from a level
weight plus the payload does not exceed the gross ve surface to each reference point located under the left
hicle weight rating. Also, ensure that the load is dis and right frame siderails.
tributed in the vehicle as evenly as possible. (3) The distance to a reference point under one
(3) Measure the tire inflation pressures and adjust frame siderail should be 3 mm (1/8 in) greater or less
the pressure, if necessary. than the point under the opposite siderail.
(4) Plot the measured vertical distances to scale on
HORIZONTAL OR DIAGONAL FRAME MEASUREMENTS a sheet of graph paper. Plot the distances so that the
Determine the frame horizontal non-square devia frame siderails are located adjacent to each other.
tion^) according to the following procedure. Join the vertical distance points.
(1) Select several reference points along one frame
siderail, preferably at the crossmember junctions.
FRAME AND BUMPERS 13 -
Fig. 3 Body HoldDowns—YJ Vehicles

- 12 FRAME AND BUMPERS
Fig. 4 Frame Alignment Dimensions—YJ Vehicles

FRAME AND BUMPERS 13 - 13
J
RN88S
F i g . 5 Frame Alignment Reference Points—Typical

FRAME REPAIR SERVICE WELDING
When necessary, conventional vehicle frames that It is recommended that electric welding equipment
are bent or twisted can be straightened by applica be used to weld frame siderails and crossmembers.
tion of heat. The temperature must not exceed 566°C/ A damaged frame component should be closely ex
1050°F. amined for hairline cracks. Repair frame component
Damaged frame siderails, crossmembers, and cracks according to the following procedure.
brackets are repaired either by straightening them (1) Drill a hole at each end of the crack with a
or by replacement. 3-mm (1/8-in) diameter drill bit.
Welded joints between the frame siderails and (2) "V-groove" the crack to allow good weld pene
crossmembers are not recommended. tration.
(3) Weld the crack.
FRAME STRAIGHTENING (4) Grind the weld surface area smooth and install
A straightening repair process should be limited to a reinforcement section at the welded area.
frame components that are not severely damaged. The flanges on reinforcement channel should
The bolts, nuts and rivets should conform to the spec be less in width than the siderail flanges. Other
ifications as the original. wise, longitudinal welds are very acceptable.
Complete transverse welds should be avoided.
FRAME COMPONENT REPLACEMENT
An improperly straightened frame component will FRAME REPAIR HARDWARE
have harmful effects on the overall frame alignment. Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
FRAME COMPONENT REPAIRS When it is more practical to substitute a bolt for a
rivet, install the next-larger-size diameter bolt to
DRILLING HOLES prevent the bolt from loosening.
Holes should not be drilled in frame siderail Conical-type lockwashers are preferred over the
flanges because this will severely reduce the frame split-ring type lockwashers. Normally, grade-5 bolts
strength. Holes drilled in the frame siderail vertical are adequate for frame repair. Grade-3 bolts (or
webs must be 38 mm (1 and 1/2 in) minimum from less) should not be used. Tightening bolts/nuts
the top and bottom flanges. with the correct torque is mandatory to adequately
Newly drilled holes should be located an acceptable "lock" the bolt, lockwasher and nut together, and to
distance away from any existing holes. prevent them from loosening.
YJ BUMPERS AND FRAME ATTACHED COMPONENTS
INDEX
page page
Generator Splash Shield . . . . . . . . . . . . . . . . . . . 15 Muffler and Tailpipe Heat Shields ............ 17
Body 18 Muffler/Tailpipe Hanger Bracket . . 17
Engine Front Support Cushion 15 Rear Bumper 18
Frame Crossmember Cover 14 Rear Jounce Bumper 18
Front Bumper 14 Service Information 14
Fuel and Brake Fluid Tube Retainer Clip . . . . . . . 16
Tow Hooks 14
Fuel Filter Shield and Bracket 17
Fuel Tank Skid Plate . .. 16 Transfer Case Skid Plate 15
SERVICE INFORMATION (3) Remove the nuts and bolts that attach the
In some cases, components in the following proce bumper rail/tow hooks to the frame rails.
dures either support, or are hidden by other compo (4) Remove the bumper rail from the frame rails.
nents. BUMPER INSTALLATION
(1) Position the front bumper on the frame rails.
FRONT BUMPER
(2) Install the bolts and attach the front bumper
The YJ front bumper is a one-piece rail (Fig. 1). A rail (and tow hooks, if equipped) to the frame rails.
front crossmember cover (Fig. 1) is also installed on (3) Tighten the bolts with 102 N-m (75 ft-lbs)
all YJ vehicles. torque,
BOLT SCREW CROSSMEMBER (4) Position the bumper extensions on the bumper
rail and install the retaining bolts.
(5) Tighten the bolts with 104 N*m (77 ft-lbs)
torque.
(6) Install the fog lamps, if equipped.
FRAME CROSSMEMBER COVER

REMOVAL
(1) Remove the screws that attach the crossmem
ber cover and support to the frame rails.
(2) Remove the crossmember cover and support
from the frame rails.
INSTALLATION
(1) Position the support and crossmember cover on
the frame rails.
(2) Install the attaching screws.
(3) Tighten the screws with 8 N*m (72 in-lbs)
torque.
J9123-211 EXTENSION W I T H T O W HOOKS RAIL TOW HOOKS

Fig. 1 Front Bumper Rail, Crossmember Cover & REMOVAL
Tow Hooks (1) Remove the two bolts that attach the tow hook
to the bumper rail and to the frame rail.
BUMPER REMOVAL
(2) Remove the tow hook.
(1) Disconnect and remove the fog lamps, if
equipped. INSTALLATION
(2) Remove the nuts and bolts that retain the (1) Position the tow hook on the bumper rail and
bumper extensions to the bumper rail and remove frame rail.
the extensions. (2) Install the attaching bolts.
(3) Tighten the bolts with 102 N«m (75 ft-lbs)
torque.
GENERATOR SPLASH SHIELD SUPPORT N U T ENGINE ENGINE BOLT NUT

CUSHION / SUPPORT SUPPORT
REMOVAL BRACKET BRACKET
(1) Remove the shield retaining nut and washer (Fig.

2) from the engine oil pan stud (2.5L engines only). BOLT
ALTERNATOR SERRATED
SPLASH SHIELD RETAINER
ENGINE
OIL PAN
STUD
FRAME
WASHER
ADAPTER
(2.5L ENGINE)
BRACKET
NUT FRAME LEFT SIDE
RAIL FRAME
ADAPTER
FWD FWD BRACKET J9213-6
Fig. 3 Engine Support Cushion—2.5L Engine

FRAME
RAIL BOLT SUPPORT SUPPORT BOLT
CUSHION CUSHION
FAN
SHROUD J9223-394
ENGINE ENGINE
Fig. 2 Generator Splash Shield SUPPORT SUPPORT
BRACKET BRACKET
(2) Pry the serrated retainers from the frame rail
holes at each side of the vehicle.
(3) Pry the serrated retainers from the fan shroud
holes (Fig. 2).
(4) Remove the shield from the vehicle.
BOLT
NUT FRAME
INSTALLATION FRAME ADAPTER
(1) Position the generator splash shield at the fan RIGHT SIDE RAIL NUT BRACKET
shroud and frame rails. FRAME LEFT SIDE
(2) Force the serrated retainers into the fan shroud RAIL J9213-7
holes.
(3) Force the serrated retainers into the frame rail Fig. 4 Engine Support Cushion—4.0L Engine
holes at each side of the vehicle. (4) Remove the support and lower the engine.
ENGINE FRONT SUPPORT CUSHION TRANSFER CASE SKID PLATE
REMOVAL REMOVAL
(1) Raise and support the engine. (1) Raise and support the transmission.
(2) Remove the nut and bolt that attach the engine (2) Remove the nuts that attach the transmission
support cushion to the engine support bracket (Figs. support cushion and torque bracket to the skid plate
3 and 4). (Fig. 5).
(3) Remove the nut and bolt that attach the sup (3) Separate the transmission support cushion from
port cushion to the frame adapter bracket. the skid plate.
(4) Remove the support cushion from the frame (4) Remove the nuts and bolts that attach the skid
adapter bracket. plate to the frame.
(5) Remove the skid plate from the vehicle.
INSTALLATION
(1) Position the support cushion on the frame INSTALLATION
adapter bracket. (1) Position the skid plate at the frame and trans
(2) Install the bolt and nut that attach the engine
mission support cushion.
support cushion to the frame adapter bracket. Tighten
(2) Attach the skid plate to the frame.
the bolt and nut with 49 N*m (36 ft-lbs) torque.
(3) Install the nuts that attach the transmission
(3) Install the bolt and nut that attach the engine
support cushion to the engine support bracket. support cushion and torque bracket to the skid plate.
Tighten the nut with 65 N-m (48 ft-lbs) torque. Tighten the nuts with 56 N-m (41 ft-lbs) torque.
MANUAL AUTOMATIC (3) Separate the fuel tank strap from the skid
TRANSMISSION TRANSMISSION plate.
MANUAL (4) Support the fuel tank and remove the skid
TRANSMISSION
plate and the pad from the vehicle.
INSTALLATION
WASHER
(1) Attach the skid plate to the fuel tank strap.
(2) Position and support the pad and skid plate un
INSU der the fuel tank.
LATOR
(3) Install the nuts to attach the skid plate to the
WASHER, straps and to the frame crossmembers. Tighten the
fuel tank strap nuts with 5 N*m (40 in-lbs) torque.
PUSH Tighten the skid plate-to-crossmember nuts with 16
NUT
N»m (138 in-lbs) torque.
(4) Remove the support from under the skid plate.
FUEL AND BRAKE FLUID TUBE RETAINER CLIP

WASHER NUT NUT MANUAL
MANUAL AUTOMATIC TRANSMISSION REMOVAL

TRANSMISSION TRANSMISSION 2.5L E N G I N E (1) Remove the fuel/brake fluid tubes from the re
4.0L E N G I N E 4.0L E N G I N E J9213-8 tainer clip grooves (Fig. 7).
FUEL RETURN TUBE FRAME SERRATED
Fig. 5 Transfer Case Skid Plate RAIL STUD
F U E L SUPPLY T U B E
(4) Remove the support and lower the transmission. ^FUEL V E N T TUBE
SERRATED
FUEL TANK SKID PLATE STUD
REMOVAL FRAME
(1) Position a support under the fuel tank skid RAIL
BRAKE
plate. FLUID TUBE
BRAKE FLUID
QUAD
(2) Remove the nuts that attach the skid plate to SERRATED
TUBE
SINGLE
the straps and to the crossmembers (Fig. 6). RETAINER SERRATED
CLIP RETAINER
FRAME CROSSMEMBER (CLAMP TYPE) CLIP
RAp x
RAIL
•C| / f
FRAME
RAIL
(CLAMP TYPE)
TAB
TRIPLE
FUEL
SERRATED
TANK R E T A I N E R CLIP
(HINGED-COVERTYPE)
QUAD FUEL FUEL
BOLT SERRATED 'SUPPLY RETURN
RETAINER R E T A I N E R CLIP TUBE TUBE J9213-4
Fig. 7 Fuel & Brake Tube Serrated Retainer

Clips—Typical
PAD
(2) Pry the serrated retainer clip outward and re
move it from the frame rail hole.
SKID
PLATE INSTALLATION
(1) Position the serrated retainer clip at the frame
rail hole.
(2) Force the serrated retainer clip inward against
NUT NUT"— ' J9123-297 the frame rail.
(3) Insert the fuel/brake fluid tubes in the retainer
Fig. 6 Fuel Tank Skid Plate clip grooves and press inward to seat them.
MUFFLER/TAILPIPE HANGER BRACKET

REMOVAL
(1) As applicable, detach the muffler or tailpipe
hanger from the insulator (Fig. 8). Remove the insu
lator from the hanger bracket.
FRAME MUFFLER INSULATOR FRAME TAILPIPE
RAIL HANGER RAIL HANGER
BRACKET BRACKET
SCREW SCREW
INSULATOR
TAILPIPE
H A N G E R CLAMP
MUFFLER HANGER FLOOR
BRACKET PANEL SCREW J9223-412
J9213-1
Fig. 8 Muffler/Tailpipe Hanger Bracket Fig. 9 Muffler & Tailpipe Heat Shield
(2) As applicable, remove the nuts and bolts, or FUEL FUEL FRAME
screws that attach the hanger bracket to the frame rail. SUPPLY FILTER RAIL
TUBE
(3) Remove the hanger bracket from the frame rail.
INSTALLATION
(1) Position the hanger bracket on the frame rail.
(2) As applicable, install the nuts and bolts, or
screws that attach the hanger bracket to the frame
rail. Tighten the nuts/screws securely.
(3) Remove the insulator from the hanger bracket.
(4) As applicable, attach the muffler or tailpipe
hanger to the insulator. SHIELD
MUFFLER AND TAILPIPE HEAT SHIELDS

REMOVAL FUEL
TANK J9213-2
(1) If necessary, remove the muffler and tailpipe
for access.
Fig. 10 Fuel Filter Shield & Bracket—Installed
(2) Remove the retaining screws and the heat
FUEL RETAINER FUEL
shields from the support bracket (Fig. 9). BOLT x BRACKET
CLIP SUPPLY
HOSE
TUBE
INSTALLATION CLAMP
(1) Position the heat shields on the support bracket
and install screws. Tighten the screws with 5 N-m
(in 44 in-lbs) torque.
(2) If removed, install the muffler and tailpipe.
FUEL FILTER SHIELD AND BRACKET
REMOVAL
(1) Remove the screws that attach the fuel filter
shield to the frame rail (Figs. 10 and 11).
(2) Remove the shield from the frame rail (Fig. 11). F R A M E RAIL
(3) Remove the nut and bolt from the fuel filter
bracket clamp. SHIELD^ SCREW J9213-3
(4) Remove the clamp and the fuel filter from the
bracket. Fig. 11 Fuel Filter Shield & Bracket—Removed
(5) Remove the screws that attach the bracket to NUTS
the frame rail.
(6) Remove the bracket from the frame rail.
INSTALLATION
(1) Position the fuel filter bracket on the frame rail.
(2) Install the screws that attach the bracket to
the frame rail. Tighten the screws with 42 N-m (31
ft-lbs) torque.
(3) Install the fuel filter in the bracket.
(4) Position the clamp on the bracket and install
bolt and nut. Tighten the nut with 8 N-m (72 in-lbs)
torque.
(5) Position the fuel filter shield from the frame rail.
(6) Install the screws that attach the fuel filter
shield to the frame rail. Tighten the screws with 42
N-m (31 ft-lbs) torque.
REAR JOUNCE BUMPER
REMOVAL
(1) Remove the screws that attach the jounce
bumper to the frame rail (Fig. 12).
FWD SCREW J9213-5
Fig. 12 Rear Jounce Bumpers

(2) Remove the jounce bumper from the frame rail.
INSTALLATION
(1) Position the jounce bumper on the frame rail.
(2) Install the screws that attach the jounce Fig. 14 Rear Bumperette & Draw Bar
bumper to the frame rail. Tighten the screws with 20
INSTALLATION
N-m (15 ft-lbs) torque.
(1) Position the spacers, brackets, draw bar and
REAR BUMPER bumperettes on the rear crossmember.
When equipped with an spare tire carrier attached (2) Install the retaining nuts, bolts and washers in
to the tailgate, a rear bumperette is attached to the the frame rear crossmember. Tighten the retaining
frame (Figs. 13 and 14). nuts and bolts securely.
BUMPERETTE AND DRAWBAR REMOVAL BODY
(1) Remove the bumperette and draw bar retaining
nuts, bolts and washers from the frame rear cross- REMOVAL
member (Figs. 14 and 15). The body is attached to the vehicle frame with
(2) Remove the bumperettes, spacers, brackets and bolts (Fig. 15). The body can be removed for repair,
draw bar from the rear crossmember. service access, or replacement, if necessary.
( 1 ) Disconnect the battery negative cable. (8) Disconnect all steering components from the
(2) Disconnect all wire harness connectors that con body.
nect body wire harnesses to the frame wire harnesses. (9) Disconnect all engine control components from
(3) Loosen the clamps and disconnect the fuel the body.
hoses from the filler nozzle (Fig. 16). (10) Disconnect all cooling system components
from the body.
PROTECTOR VEHICLE CLAMP HOSE (11) Disconnect all brake system components from
the body.
(12) Disconnect all remaining component connec
tions between the body and the frame.
(13) Remove bolts from the frame and body. The
bolts are accessible from the underside of the frame
at the following locations:
• at the rear of each frame rail;
• at each rear quarter crossmember wedge;
• at the side of each frame rail and
• at the center of the front crossmember.
(14) Identify, mark and retain the attaching hard
ware for installation reference.
(15) Remove the body from the frame.
SCREW J9123-62
INSTALLATION
Fig. 16 Fuel Hoses & Clamps (1) Position body on the frame.
(2) Install the body-to-frame attaching hardware.
(4) Disconnect the parking brake cable. (3) Connect the exhaust hangers, fuel tank hoses
(5) Support the exhaust system and disconnect the and parking brake cable.
support hangers. (4) Connect all the wire harness connectors.
(6) Disconnect all suspension components from the (5) Connect all disconnected vehicle components to
body. the body. Refer to the applicable procedures within
(7) Disconnect all drive train components from the this manual.
body. (6) Connect the battery negative cable.
4 FUEL SYSTEM 14 - 1
FUEL SYSTEM
CONTENTS
page page
ACCELERATOR PEDAL AND THROTTLE CABLE . . . 16 MPI SYSTEM-COMPONENT REMOVAL/
FUEL DELIVERY SYSTEM 2 INSTALLATION 68
FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MPI SYSTEM-GENERAL DIAGNOSIS 32
GENERAL INFORMATION 1 SPECIFICATIONS 66
MPI SYSTEM-COMPONENT DESCRIPTION/
SYSTEM OPERATION 17
GENERAL INFORMATION
Throughout this group, references are made to par age as a result of heavy knock operation may not be
ticular vehicle models by alphabetical designation or covered by the new vehicle warranty.
by the particular vehicle nameplate. A chart showing In addition to using unleaded gasoline with the
a breakdown of the alphabetical designations is in proper octane rating, those that contain deter
cluded in the Introduction section at the beginning of gents, corrosion and stability additives are rec
this manual. ommended. Using gasolines that have these
The Fuel System consists of: the fuel tank, an additives will help improve fuel economy, reduce
electric (fuel tank mounted) fuel pump and fuel fil emissions and maintain vehicle performance. Gener
ter. It also consists of fuel tubes/lines/hoses, vacuum ally, premium unleaded gasolines contain more addi
hoses, throttle body and fuel injectors. tive than regular unleaded gasolines.
The Fuel Delivery System consists of: the electric Poor quality gasoline can cause problems such as
fuel pump, ballast resistor and relay (XJ only), fuel hard starting, stalling and stumble. If you experience
filter, fuel tubes/lines/hoses, fuel rail, fuel injectors these problems, use another brand of gasoline before
and fuel pressure regulator. considering service for the vehicle.
A Fuel Return System is used on all vehicles.
The system consists of: the fuel tubes/lines/hoses that GASOLINE/OXYGENATE BLENDS
route fuel back to the fuel tank. Some fuel suppliers blend unleaded gasoline with
The Fuel Tank Assembly consists of: the fuel materials that contain oxygen such as alcohol, MTBE
tank, filler tube, fuel gauge sending unit/electric fuel and ETBE. The type and amount of oxygenate used
pump module, a pressure relief/rollover valve and a in the blend is important. The following are gener
pressure-vacuum filler cap. ally used in gasoline blends:
Also to be considered part of the fuel system is the
ETHANOL
Evaporation Control System. This is designed to
reduce the emission of fuel vapors into the atmo Ethanol (Ethyl or Grain Alcohol) properly blended,
sphere. The description and function of the Evapora is used as a mixture of 10 percent ethanol and 90
tive Control System is found in Group 25, Emission percent gasoline. Gasoline with ethanol may be
Control Systems. used in your vehicle.
F U E L USAGE S T A T E M E N T METHANOL
Your vehicle was designed to meet all emission
regulations and provide excellent fuel economy using CAUTION: DO N O T U S E G A S O L I N E S CONTAINING
high quality unleaded gasoline. Only use unleaded M E T H A N O L . Use of methanol/gasoline blends may re
gasolines having a minimum posted octane of 87. sult in starting and driveability problems. In addition,
If your vehicle develops occasional light spark damage may be done to critical fuel system compo
knock (ping) at low engine speeds, this is not harm nents.
ful. However, continued heavy knock at high
speeds can cause damage and should be re Methanol (Methyl or Wood Alcohol) is used in a va
ported to your dealer immediately. Engine dam riety of concentrations blended with unleaded gaso-
14-2 FUEL SYSTEM J
line. You may encounter fuels containing 3 percent CLEAN AIR GASOLINE
or more methanol along with other alcohols called co- Many gasolines are now being blended that con
solvents. 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. These
oline blends are not the responsibility of Chrysler
new blends provide a cleaner burning fuel and some
Corporation. They may not be covered by the vehicle
are referred to as Reformulated Gasoline.
warranty.
In areas of the country where carbon monoxide lev
MTBE/ETBE els are high, gasolines are being treated with oxy
Gasoline and MTBE (Methyl Tertiary Butyl Ether) genated materials such as MTBE, ETBE and
blends are a mixture of unleaded gasoline and up to ethanol.
15 percent MTBE. Gasoline and ETBE (Ethyl Ter Chrysler Corporation supports these efforts toward
tiary Butyl Ether) are blends of gasoline and up to cleaner air and recommends that you use these gas
17 percent ETBE. Gasoline blended with MTBE or olines as they become available.
ETBE may be used in your vehicle.
FUEL DELIVERY SYSTEM
NDEI
page page
Fuel Filter 9 Fuel Pump Module 2
Fuel Pressure Leak Down Test 8 Fuel System Pressure Test ! 6
Fuel Pressure Release Procedure 5 Fuel Tubes/Lines/Hoses and Clamps . . . . . . . . . . 10
Fuel Pump Capacity Test 8 Quick-Connect Fittings 10
Fuel Pump Control 5
FUEL PUMP MODULE is not operating, system fuel pressure of 131-269 kPa
The fuel pump module is installed in the top of the (19-39 psi) is maintained. This is done by the fuel
fuel tank. The fuel pump module contains the follow pump outlet check valve and the vacuum assisted
ing components: fuel pressure regulator.
• Electric fuel pump
• Fuel pump reservoir REMOVAL-XJ MODELS
• In-tank fuel filter The fuel pump/gauge sender unit assembly can be
• Fuel gauge sending unit removed from the fuel tank without removing the
• Fuel supply and return tube connections tank from the vehicle.
The fuel pump used on all vehicles is a gear/rotor
WARNING: T H E F U E L S Y S T E M I S U N D E R A CON
type pump. It is driven by a permanent magnet 12
S T A N T P R E S S U R E ( E V E N W I T H T H E ENGINE OFF).
volt electric motor that is immersed in the fuel tank.
The electrical pump is integral with the fuel sender B E F O R E SERVICING T H E F U E L P U M P M O D U L E ,
unit. The pump/sender assembly is installed inside T H E FUEL SYSTEM PRESSURE MUST B E R E
the fuel tank. LEASED. R E F E R T O T H E FUEL PRESSURE R E
L E A S E P R O C E D U R E IN T H I S G R O U P .
The fuel pump has a check valve at the outlet end
that consists of a ball held against a seat by force ap
plied from a spring. When the pump is operating, WARNING: E X T I N G U I S H A L L TOBACCO SMOKING
fuel pressure overcomes spring pressure and forces P R O D U C T S B E F O R E SERVICING T H E F U E L S Y S
the ball off its seat, allowing fuel to flow. When the T E M . K E E P O P E N F L A M E AWAY FROM F U E L S Y S
pump is not operating, spring pressure forces the ball T E M COMPONENTS.
back against the seat preventing fuel backflow
through the pump. (1) Remove fuel filler cap. Perform the Fuel Pres
Fuel system pressure is maintained at approxi sure Release Procedure as outlined in this group.
mately 214 kPa (31 psi). This is when the pump is (2) Disconnect negative battery cable.
operating and vacuum is supplied to the fuel pres (3) Using an approved portable gasoline siphon/
sure regulator. If vacuum is not supplied to the pres storage tank, drain fuel tank until fuel level is below
sure regulator, fuel pressure will be approximately one quarter (1/4) full.
55-69 kPa (8-10 psi) higher. This may be due to a
(4) Raise and support vehicle.
broken or clogged vacuum line. When the fuel pump
FUEL SYSTEM 14 - 3
WARNING: W R A P S H O P T O W E L S A R O U N D F U E L
H O S E S T O A B S O R B ANY F U E L S P I L L A G E DURING
F U E L T A N K REMOVAL. OUTLET
HOSE
(5) Disconnect fuel vent supply and return tubes
from fittings on fuel pump module.
(6) Disconnect fuel pump module electrical harness GAUGE
FLOAT
connector from main harness.
(7) Using a brass punch and hammer, remove fuel
pump module lock ring by carefully tapping it coun
terclockwise (Fig. 1).
BRASS
PUNCH
WIRE TERMINALS
INLET
FILTER
TOP MOUNTING
BRACKET N U T
MPI
FUEL
PUMP J8914-62
Fig. 2 Fuel Pump Module—XJ

Models—Disassemble/Assemble
INSTALLA TION—XJ MODELS
Whenever the fuel pump is replaced, the fuel
J9014-34 pump inlet filter must also be replaced.
(1) Install new fuel pump inlet filter onto fuel
Fig. 1 Removing Lock Ring—XJ Models—Typical pump.
(8) Remove fuel pump module and O-ring seal. (2) Install fuel pump module assembly and new
Discard old O-ring and fuel pump module inlet filter. O-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. 3 ) .
(1) Remove and discard fuel pump inlet filter. FUEL P U M P / G A U G E
The wire terminals to the fuel pump motor are dif "SENDER U N I T
ferent in size and cannot be connected to the wrong
terminal.
(2) Disconnect fuel pump terminal wires.
(3) Remove fuel pump outlet hose and clamp. Re
place the hose if it shows any signs of fatigue or fail
ure.
(4) Remove fuel pump top mounting bracket nut.
Remove fuel pump (Fig. 2 ) . STOPPER
A S S E M B L Y — X J MODELS
Whenever the fuel pump is replaced, the fuel pump
inlet filter (sock) must also be replaced.
(1) Place fuel pump top mounting bracket over top
of pump.
(2) Position fuel pump into lower bracket. Slide
stud of top bracket through hole in fuel pump side
bracket. Tighten fuel pump top mounting nut.
(3) Install new fuel pump outlet hose. Secure with J8914-63
new clamps.
(4) Connect wire terminals to motor. Fig. 3 Fuel Pump Module—XJ Models—Installation
(5) Install new fuel pump inlet filter.
14 - 4 FUEL SYSTEM J
(3) Using a brass punch and a hammer, install DISASSEMBLY—YJ MODELS

lock ring. Carefully tap lock ring clockwise until it (1) Remove and discard fuel pump inlet filter (Fig.
seats against stop on fuel tank. 5).
(4) Connect fuel supply and return hoses to fittings
on fuel pump module. Tighten hose clamps.
(5) Connect fuel pump module electrical harness
connector to main harness connector.
(6) Lower vehicle.
(7) Fill fuel tank. Install fuel tank cap.
(8) Connect negative battery cable.
( 9 ) Start vehicle and inspect for leaks.
REMOVAL-YJ MODELS
The fuel tank must be removed to remove the fuel
pump module.
WARNING: THE FUEL SYSTEM IS UNDER A CON

STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE RE
Fig. 5 Fuel Pump Module—YJ Models
LEASED. REFER TO THE FUEL PRESSURE RE
LEASE PROCEDURE IN THIS GROUP. The wire terminals to the fuel pump motor are dif
ferent in size and cannot be connected to the wrong
terminal.
WARNING: EXTINGUISH ALL TOBACCO SMOKING (2) Disconnect fuel pump terminal wires from
PRODUCTS BEFORE SERVICING THE FUEL SYS pump.
TEM. KEEP OPEN FLAME AWAY FROM FUEL SYS (3) Remove fuel pump outlet hose and clamp (Fig.
TEM COMPONENTS. 6). Replace the hose if it shows any signs of fatigue
or failure.
(1) Remove negative battery cable. (4) Remove fuel pump top mounting bracket nut
(2) Remove fuel filler cap. Perform the Fuel Pres (Fig. 6 ) . Remove fuel pump.
sure Release Procedure as outlined in this group.
(3) Remove fuel tank. Refer to Fuel Tank Remov- TOP MOUNTING HOSE
a l - Y J Models.
(4) Remove fuel pump module assembly.
(5) Remove mounting screws. Lift assembly and
gasket out of fuel tank. Discard old gasket (Fig. 4).
M O U N T I N G SCREWS
Fig. 6 Fuel Pump Removal/Installation— YJ Models

ASSEMBLY-YJ MODELS
Whenever the fuel pump is replaced, the fuel pump
inlet filter (sock) must also be replaced.
FUEL PUMP/GAUGE SENDER UNIT J9014-33
(1) Place fuel pump top mounting bracket over top
Fig. 4 Fuel Pump Module—Remove/Install— YJ of pump.
Models (2) Position fuel pump into lower bracket. Slide
stud of top bracket through hole in fuel pump side
(6) Remove and discard fuel pump inlet filter. bracket. Tighten fuel pump top mounting nut.
J FUEL SYSTEM 14 - 5
(3) Install new fuel pump outlet hose. Secure with

new clamps.
(4) Connect wire terminals to motor.
(5) Install new fuel pump inlet filter.
INSTALLA TiON- YJ MODELS

(1) Install a new fuel pump inlet filter.
(2) Install fuel pump module assembly with a new
gasket between the assembly and tank. Tighten
mounting screws to 2 N*m (18 in. lbs.) torque.
(3) Install fuel tank. Refer to Fuel Tank Installa
tion—YJ Models.
(4) Fill fuel tank. Install fuel tank cap.
(5) Install negative battery cable.
(6) Start vehicle and check for leaks.
FUEL PUMP CONTROL Fig. 8 Ballast Resistor—XJ Models Only
MJ MODELS
The Powertrain Control Module (PCM) energizes
the fuel pump through the fuel pump relay. (The
PCM was formerly referred to as the SBEC or engine
controller). Battery voltage is applied to the relay
from the ignition switch. The relay is energized when
a ground is provided by the PCM. The relay is lo
cated in the Power Distribution Center (PDC) next to
the coolant recovery bottle (Fig. 7). For the location
of fuel pump relay within PDC, refer to label under
PDC cover.
Fig. 9 Ballast Resistor Bypass Relay—XJ Models

YJ MODELS
The Powertrain Control Module (PCM) energizes
the fuel pump through the fuel pump relay. (The
PCM was formerly referred to as the SBEC or engine
controller). Battery voltage is applied to the relay
a ground is provided by the PCM. The relay is lo
cated in the Power Distribution Center (PDC) next to
J9114-91
the battery (Fig. 10). The PCM energizes the fuel
pump through the fuel pump relay during all operat
Fig. 7 PDC-XJ Models ing conditions.
A ballast resistor is installed (in-line) between the
FUEL P R E S S U R E RELEASE PROCEDURE
relay and the fuel pump on XJ models (Fig. 8). The
PCM energizes the fuel pump through the fuel pump WARNING: T H E F U E L S Y S T E M I S U N D E R CON
relay during all operating conditions except wide S T A N T F U E L P R E S S U R E ( E V E N W I T H T H E ENGINE
open throttle (WOT). OFF) O F A P P R O X I M A T E L Y 131-269 K P A (19-39
During wide open throttle (WOT) operation, the PSI). T H I S P R E S S U R E M U S T B E R E L E A S E D B E
ballast resistor is bypassed. The fuel pump is ener
F O R E SERVICING ANY F U E L S U P P L Y OR F U E L R E
gized through the ballast resistor bypass relay. The
T U R N S Y S T E M COMPONENT.
ballast resistor bypass relay is located on a bracket
next to the Power Distribution Center (Fig. 9). Refer (1) Disconnect negative battery cable.
to Group 8W, Wiring Diagrams for circuit layout.
(8) After fuel pressure has been released, remove

the hose from the test port.
(9) Install protective cap to fuel test port.
FUEL SYSTEM PRESSURE TEST

The fuel system is equipped with a vacuum as
sisted fuel pressure regulator (Fig. 12). With engine
at idle speed, system fuel pressure should be approx
imately 214 kPa (31 psi) with the vacuum line con
nected to the regulator. With the vacuum line
disconnected from the regulator, fuel pressure should
be approximately 269 kPa (39 psi). This is 55-69 kPa
(8-10 psi) higher.
(1) Remove the protective cap at the fuel rail (Fig.
11). Connect the 0-414 kPa (0-60 psi) fuel pressure
gauge (from Gauge Set 5069) to test port pressure fit
Fig. 10 PDC-YJ Models ting on fuel rail (Fig. 13).
(2) Remove fuel tank filler neck cap to release fuel
tank pressure.
WARNING; DO NOT A L L O W F U E L T O S P I L L ONTO

T H E ENGINE I N T A K E O R E X H A U S T MANIFOLDS.
P L A C E S H O P T O W E L S U N D E R AND AROUND T H E
P R E S S U R E PORT T O ABSORB F U E L WHEN T H E
P R E S S U R E I S R E L E A S E D FROM T H E F U E L R A I L .
WARNING: W E A R P R O P E R E Y E P R O T E C T I O N
WHEN RELEASING F U E L S Y S T E M P R E S S U R E .
(3) Remove protective cap from pressure test port

on the fuel rail (Fig. 11).
Fig. 12 Fuel Pressure Regulator—Typical
Fig. 11 Pressure Test Port—Typical

(4) Obtain the fuel pressure gauge/hose assembly
from fuel pressure gauge tool set 5069. Remove the
Fig. 13 Fuel Pressure Test Connection—Typical
gauge from the hose.
(5) Place one end of hose (gauge end) into an ap (2) Note pressure gauge reading. Fuel pressure
proved gasoline container. should be approximately 214 kPa (31 psi) at idle.
(6) Place a shop towel under the test port. (3) Disconnect vacuum line (hose) at fuel pressure
(7) To release fuel pressure, screw the other end of regulator (Fig. 12). Note gauge reading. With vac-
hose onto the fuel pressure test port.
uum line disconnected, fuel pressure should rise to SPECIAL
approximately 269 kPa (39 psi). TOOL
Fuel pressure should be approximately 55-69 kPa #6539 (5/16")
(8-10 psi) higher with vacuum line removed from

regulator. If not, inspect pressure regulator vacuum
line for leaks, kinks or blockage. If vacuum line
checks OK and fuel pressure does not rise approxi
mately 8-10 psi after disconnecting vacuum line, re
place fuel pressure regulator.
The fuel pressure regulator is not adjustable.
(4) If fuel pressure exceeds 45 psi, check fuel re
turn line for kinks or obstructions.
If the previous tests checked good, fuel pump pres
sure is correct. If pump pressure was low, proceed as
follows: J9314-26
(5) Release fuel system pressure. Refer to the pre
vious Fuel Pressure Release Procedure in this group. Fig. 15 Adapter Tool—Typical Connection
(6) Disconnect the 5/16 inch fuel return line quick-
proximately 75 psi within two (2) seconds. DO NOT
connect fitting at fuel rail. To disconnect quick-con
nect fitting from fuel rail, press on both tabs located pinch hose for longer than three seconds.
on sides of fitting (Fig. 14) and remove fitting at fuel If fuel pump pressure rises to approximately 75 psi
rail. within two seconds, pressure is operating at its max
imum and is correct.
FITTING TAB If fuel pump pressure does not rise to approxi
mately 75 psi within two seconds, proceed as follows:
FUEL T U B E
(9) Release fuel system pressure. Refer to the pre
vious Fuel Pressure Release Procedure in this group.
(11) Disconnect fuel supply line at inlet (fuel tank
side) of fuel filter. Connect Fuel Line Pressure Test
Adapter Tool number 6631 (3/8 in.) between fuel fil
ter and fuel supply line.
WARNING: T H E F U E L S Y S T E M P R E S S U R E IN THE
FOLLOWING T E S T MAY E X C E E D 100 P S I . B E F O R E
S T A R T I N G T E S T , V E R I F Y GOOD CONNECTIONS A T
TAB E N D S O F A D A P T E R T O O L 6631. B E S U R E T O O L I S
O-RINGS RETAINER J9014-3 L O C K E D ONTO F U E L F I L T E R AND F U E L S U P P L Y
L I N E . P U L L F I R M L Y ON E N D S O F T O O L TO V E R
Fig. 14 Removing Quick-Connect Fitting
IFY.
Connect Fuel Line Pressure Test Adapter Tool
number 6539 (5/16 in.) between the disconnected fuel (12) To activate the fuel pump and pressurize the
return line and fuel rail (Fig. 15). system, obtain the DRB II scan tool. Refer to the ap
propriate Powertrain Diagnostic Procedures service
WARNING; T H E F U E L S Y S T E M P R E S S U R E IN T H E manual for DRB II operation.
FOLLOWING T E S T MAY E X C E E D 100 P S I . B E F O R E MOMENTARILY pinch the rubber hose portion of
S T A R T I N G T E S T , V E R I F Y GOOD CONNECTIONS A T adapter tool 6631. Pressure should rise to approxi
E N D S OF A D A P T E R T O O L 6539. B E S U R E T O O L I S mately 75 psi within two (2) seconds. DO NOT pinch
L O C K E D ONTO F U E L R A I L AND F U E L R E T U R N
hose for longer than three seconds.
L I N E . P U L L F I R M L Y ON E N D S O F T O O L T O V E R
If fuel pump pressure now rises to approximately
IFY.
75 psi within two seconds, but this pressure could not
(7) To activate the fuel pump and pressurize the be met at the fuel rail, check for a plugged or re
system, obtain the DRB II scan tool. Refer to the ap stricted fuel filter. Also check the fuel supply line be
propriate Powertrain Diagnostic Procedures service tween fuel filter and fuel rail for kinks or
manual for DRB II operation. obstructions. Proceed to the following Fuel Pump Ca
(8) M O M E N T A R I L Y pinch the rubber hose por pacity Test.
tion of adapter tool 6539. Pressure should rise to ap-
F U E L P U M P CAPACITY T E S T (3) Shut engine off. Observe and record fuel pres
Before performing this test, verify fuel pump pres sure reading on gauge. Leave fuel pressure gauge
sure by performing the previous tests. connected. Allow engine to set for 30 minutes and
(1) Release the fuel system pressure from fuel sys then compare the fuel pressure reading on the gauge
tem. Refer to the previous Fuel Pressure Release with the reading taken when engine was shut down.
Procedure in this group. A pressure drop of up to 138 kPa (20 psi) within 30
(2) Disconnect the fuel supply line at fuel rail near minutes is within specifications.
pressure regulator. (4) If the fuel pressure drop is within specifica
(3) Connect Fuel Line Pressure Test Adapter Tool tions, the fuel pump outlet check valve and fuel pres
number 6631 (3/8 in.) into the disconnected fuel sup sure regulator are both operating normally.
ply line. Insert the other end of tool 6631 into an ap (5) If fuel pressure drop is greater than 138 kPa
proved gasoline container. (20 psi), it must be determined if this drop is being
(4) To activate the fuel pump and pressurize the caused by (in-tank mounted) fuel pump outlet check
system, obtain the DRB II scan tool. Refer to the ap valve or fuel pressure regulator. Proceed to next step.
propriate Powertrain Diagnostic Procedures service (6) Release the fuel system pressure from fuel sys
manual for DRB II operation. tem. Refer to the previous Fuel Pressure Release
A good fuel pump will deliver at least 1 liter of fuel Procedure in this group.
per minute. (7) Disconnect both fuel lines at fuel rail near fuel
pressure regulator.
FUEL PRESSURE LEAK DOWN TEST (8) Connect Fuel Line Pressure Test Adapter Tool
number 6631 (3/8 in.) between the disconnected fuel
ENGINE OFF supply line and fuel rail (Fig. 17).
Abnormally long periods of cranking to restart a (9) Connect Fuel Line Pressure Test Adapter Tool
hot engine that has been shut down for a short pe number 6539 (5/16 in.) between the disconnected fuel
riod of time may be caused by: return line and fuel rail (Fig. 17).
• Fuel pressure bleeding past the fuel pressure reg
ulator.
• Fuel pressure bleeding past the check valve in the
outlet end of the fuel tank mounted fuel pump.
(1) Remove protective cap at fuel rail test port
(Fig. 16). With the engine off, connect an accurate
0-689 kPa (0-100 psi) fuel gauge to the pressure test
port fitting on the fuel rail. The fitting on the pres
sure tester must be in good condition and free of any
leaks before performing this test.
Fig. 17 Adapter Tools—Typical Connections

(10) Start engine. Observe and record fuel system
pressure.
(11) Shut engine off.
(12) Clamp off the rubber hose portion of adapter
tool number 6539 connected to the fuel return line.
Allow engine to set for 30 minutes. If pressure has
dropped more than 138 kPa (20 psi) in 30 minutes,
pressure is bleeding past the (in-tank mounted) fuel
pump outlet check valve. Replace Fuel Pump Module
Fig. 16 Fuel Pressure Test Port—Typical assembly. Refer to Fuel Pump Module removal and
(2) Start the vehicle and let engine idle. Check installation in this group. If pressure drop is within
fuel pressure reading on gauge. Fuel pressure should specifications, proceed to next step.
be within specifications. Refer to the previous Fuel (13) Clamp off the rubber hose portion of adapter
System Pressure Tests. tool number 6631 connected to the fuel supply line.
FUEL SYSTEM 14-1
a
Allow engine to set for 30 minutes. If pressure has
dropped more than 138 kPa (20 psi) in 30 minutes,
pressure is bleeding past the fuel pressure regulator.
Replace fuel pressure regulator. Refer to Fuel Rail
removal and installation in the Component Removal/
Installation section of this group.
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag
nose with this system. The Powertrain Control Mod
ule (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam
timing, vacuum leaks, etc. If engine performance
problems are encountered and diagnostic trouble
codes are not displayed, the problem may be mechan
ical rather than electronic.
FUEL FILTER
The fuel filter protects the fuel injectors and fuel
pressure regulator from dirt, water and other foreign
matter. The filter is located under the vehicle along
the frame rail (Figs. 18 or 19). Replace fuel filter at
Fig. 19 Fuel Filter-XJ Models
intervals specified in the Lubrication and Mainte
nance Schedule chart found in Group 0, Lubrication WARNING: F U E L P R E S S U R E M U S T B E R E L E A S E D
and Maintenance. B E F O R E DISCONNECTING A N Y F U E L S Y S T E M
COMPONENT.
(2) Release fuel system pressure. Refer to Fuel

Pressure Release Procedure in this group.
(4) On YJ models remove the fuel filter shield
(Fig. 18).
(5) Remove hoses and clamps from inlet and outlet
sides of filter (Figs. 18 or 19).
(6) Remove retaining strap bolt.
(7) Remove filter from vehicle.
INSTALLATION
CAUTION: T h e ends of the fuel filter are marked for

correct installation. Install filter with the end marked
IN towards fuel tank and the end marked O U T to
wards engine.
(1) Place fuel filter in retaining strap with the

J8914-4 marked ends in the correct position.
(2) Install retaining strap bolt and tighten to 12
Fig. 18 Fuel Filter and Shield— YJ Models N*m (106 in. lbs.) torque.
REMOVAL (3) Install inlet and outlet hoses and hose clamps.
Tighten clamps securely.
WARNING: T H E F U E L S Y S T E M I S U N D E R CON (4) On YJ models, install fuel filter shield (Fig.
S T A N T F U E L P R E S S U R E ( E V E N W I T H T H E ENGINE 18).
OFF) O F A P P R O X I M A T E L Y 131-269 K P A (19-39 (5) Lower vehicle.
PSI). T H I S P R E S S U R E M U S T B E R E L E A S E D B E (6) Connect negative battery cable.
F O R E SERVICING T H E F U E L F I L T E R . (7) Start engine and check for leaks.
(1) Disconnect negative battery cable. Remove fuel
filler cap.
14-10 FUEL SYSTEM J
F U E L T U B E S / L I N E S / H O S E S AND C L A M P S
Also refer to Quick-Connect Fittings in this sec
tion.
WARNING; T H E F U E L S Y S T E M I S U N D E R A CON
S T A N T P R E S S U R E (EVEN W I T H T H E ENGINE O F F ) .
B E F O R E SERVICING ANY F U E L S Y S T E M H O S E S ,
FITTINGS OR LINES, T H E F U E L S Y S T E M P R E S
SURE MUST B E RELEASED. R E F E R TO T H E FUEL
PRESSURE RELEASE PROCEDURE IN T H I S
GROUP.
Inspect all hose connections such as clamps, cou

plings and fittings to make sure they are secure and
leaks are not present. The component should be re
placed : immediately if there is any evidence of degra
dation that could result in failure. Fig. 20 Quick-Connect Fittings
Avoid contact of any fuel tubes/hoses with other ve
FITTING TAB
hicle components that could cause abrasions or scuff
ing, .he plastic fuel tubes are properly
routed to prevent pinching and to avoid heat sources.
CAUTION: T h e tubes/hoses used on fuel injected

vehicles are of a special construction. T h i s i s due
to the higher fuel pressures and the possibility of
contaminated fuel in this system. If it i s necessary
to replace these tubes/hoses, only tubes/hoses
marked E F M / E F I may be used.
CAUTION: T h e hose clamps used on fuel injected

vehicles are of a special rolled edge construction to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may Fig. 21 Quick-Connect Fitting Components
cut into the hoses and cause high pressure fuel
leaks. The retainer has two tabs. To disconnect the quick-
connect fitting, squeeze the tabs against the fuel
Use new original equipment type hose clamps. tube. Pull the fitting off of the quick-connect fitting/
Tighten hose clamps to 1 N*m (10 in. lbs.) torque. tube assembly. The retainer will stay on the fuel
tube when the tube is disconnected. The O-rings and
QUICK-CONNECT FITTINGS spacer will remain in the connector.
Also refer to the previous Fuel Tubes/Lines/Hoses
and Clamps. CAUTION: When ever a fuel tube quick-connect fit
ting i s disconnected, the O-rings, spacer and re
CAUTION: T h e O-ring and spacer assembly must be tainer M U S T be replaced.
replaced when ever the quick-connect fittings are
disassembled. The O-rings and spacer can be removed with the
bent end of an L-shaped paper clip.
Quick-connect fittings are used at the inlet and
outlet ports of the fuel rail (Fig. 20). The fittings con O-RING REPLACEMENT
sist of two O-rings, a spacer (installed between A repair kit consisting of replacement O-rings,
O-rings) and an O-ring retainer (Fig. 21).
spacer and retainer is available through the parts de
DISASSEMBLY partment. The replacement parts are installed on a
disposable plastic plug. Install the replacement kit as
WARNING; F U E L P R E S S U R E M U S T B E R E L E A S E D follows:
B E F O R E DISCONNECTING A N Y F U E L S Y S T E M
COMPONENT.
J FUEL SYSTEM 14-11
(1) Push kit/disposable plug assembly into quick- ASSEMBLY

connect fitting until an audible click sound is heard (1) Push fuel tube into quick-connect fitting until
(Fig. 22). an audible click is heard (Fig. 23).
REPLACEMENT KIT QUICK CONNECT FUEL TUBE
FITTING
J9014-125
J8914-10
Fig. 22 Repair Kit Installation Fig. 23 Fuel Tube-to-Fitting Connection

(2) Grasp end of disposable plug and pull outward (2) Verify that connection is secure by firmly pull
to remove it from fitting. ing back on fuel tube (Fig. 23). The tube should be
locked in place.
FUEL TANKS
page page
Fuel Gauge Sending Unit 14 General Information 11
Fuel Tank 12 Heat Shields 12
Fuel Tank Filler Tube Cap 12 No-Lead Fuel Tank Filler Tube 12
Fuel Tank Pressure Relief/Rollover Valve . . . . . . 14
GENERAL INFORIATION Inspect all hose/tube connections for completeness.

All vehicles pass a full 360 degree rollover test Be sure that leaks are not present. Replace any hose
without fuel leakage. To accomplish this, fuel and that is cracked, scuffed, swelled, has rubbed against
vapor flow controls are required for all fuel tank con other vehicle components or shows any other sign of
nections. wear that could lead to failure. If it is necessary to
All models are equipped with a pressure relief/roll replace a hose, only hose marked EFM/EFI may be
over valve mounted in the top of the fuel pump mod used.
ule. The return line from the fuel pump to the fuel When installing hoses, be sure that they are routed
tank contains a one-way check valve. away from contact with other vehicle components.
An evaporative control system prevents raw fuel The hose clamps used on fuel injected vehicles are
vapor from escaping into the atmosphere. Fuel va of a special rolled edge construction to prevent the
pors from the fuel tank are collected in the EVAP edge of the clamp from cutting into the hose. Only
canister. When the engine is operating, the vapors these rolled edge type clamps may be used on this
are drawn into the intake manifold to be used in system. Other types of clamps may cut into the hoses
combustion. Refer to Group 25, Emission Control and cause high pressure fuel leaks.
System for more information.
14 - 1 2 FUEL SYSTEM J
FUEL TANK CAPACITIES PSI). T H I S P R E S S U R E M U S T B E R E L E A S E D B E
F O R E SERVICING F U E L T A N K .
FUEL TANK GALLONS* LITERS*

REMOVAL^ XJ MODELS
XJ 20.02 76
Perform the preceding Fuel System Pressure Re
YJ 20.0 76 lease Procedure.
(1) Disconnect negative battery cable.
YJ 15.0 57
(2) Remove the fuel filler cap. Using an approved
'Nominal refill capacities are shown. A variation may be portable gasoline siphon/storage tank, drain fuel
observed from vehicle to vehicle due to manufacturing tank.
tolerances, ambient temperature and refill procedure.
J9314-143 (4) Disconnect fuel fill hose and fill vent hose from
filler neck (Fig. 1).
NO-LEAD FUEL T A N K FILLER TUBE
All vehicles are designed to operate using Un
leaded fuels. The diameter of the opening in the fuel
tank filler neck is sized to only accept unleaded fuel
nozzles. Gasoline station pumps for unleaded and
leaded fuels have different size nozzles. Leaded fuel
nozzles are larger in diameter than unleaded nozzles.
The fuel tank filler neck opening is also equipped
with a deflector, which the smaller unleaded nozzle
pushes back upon entering the filler neck. The de
flector will prevent the larger diameter leaded fuel
nozzles from entering the filler neck and will deflect
fuel away from the filler neck. This happens if filling
of the tank with leaded fuel is attempted.
A label is attached to the instrument panel under
the fuel gauge that reads UNLEADED FUEL ONLY
as a reminder to the driver. A similar label is located
near the fuel tank filler.
F U E L T A N K F I L L E R T U B E CAP
The loss of any fuel or vapor out of the filler neck
J8914-17
is prevented by the use of a safety filler cap. This
will release only under pressure of 10.9 to 13.45 kPa Fig. 1 Filler Neck Hoses—XJ Models
(1.58 to 1.95 psi). The vacuum release is between .97
and 2.0 kPa (.14 and .29 psi). This cap must be re (5) Disconnect fuel pump module wire connector.
placed by a similar unit if replacement is necessary. Remove tie straps securing connector harness to fuel
supply and return tubes.
CAUTION: Remove the fuel tank filler tube cap prior
to removing or repairing fuel lines to relieve fuel WARNING: W R A P S H O P T O W E L S AROUND F U E L
tank pressure. H O S E S TO A B S O R B ANY F U E L S P I L L A G E DURING
F U E L T A N K REMOVAL.
HEAT SHIELDS (6) Disconnect fuel tank vent hose from vent tube.
The sheet metal heat shields may have to be re (7) Disconnect fuel supply and return hoses from
moved when servicing the fuel tank, fuel lines or va tubes.
por vent line. The heat shields must be installed to (8) If equipped, remove skid plate (Fig. 2).
protect the lines and tank from the heat of the ex (9) Remove fuel tank shield (Fig. 3).
haust system. Refer to Group 11, Exhaust System (10) Center a transmission jack under the fuel
and Intake Manifold for proper installation. tank.
(11) Remove support strap nuts. Move straps away
FUEL TANK from tank (Fig. 3).
(12) Lower fuel tank on transmission jack.
WARNING: T H E F U E L S Y S T E M I S U N D E R CON
S T A N T F U E L P R E S S U R E ( E V E N W I T H T H E ENGINE INSTALLA TION-XJ MODELS
OFF) OF A P P R O X I M A T E L Y 131-269 KPA (19-39 (1) Raise fuel tank into position. Connect fuel fill
(9) Lower vehicle.

(10) Fill fuel tank. Install filler cap.
(11) Connect negative battery cable to battery.
(12) Start vehicle and inspect for leaks.
REMOWML—YJ MODELS
WARNING: E X T I N G U I S H A L L TOBACCO SMOKING

P R O D U C T S B E F O R E SERVICING T H E F U E L S Y S
T E M . K E E P O P E N F L A M E AWAY F R O M F U E L S Y S
T E M COMPONENTS.
(1) Disconnect negative battery cable.

(2) Remove the fuel filler cap. Using an approved
portable gasoline siphon/storage tank, drain fuel
tank.
(4) Using a small straight blade screwdriver, pull
back the stems of the push clips that secure the fuel
M O U N T I N G BOLTS
filler neck shroud (located at bottom of left rear
J8914-19
wheel well) in place (Fig. 4). This unlocks the push
Fig. 2 Skid Plate-XJ Models
clip allowing them to be removed by pulling assem
bly out of shroud. Remove shroud.
Fig. 4 Fuel Filler Neck Shroud— YJ Models
(5) Disconnect fuel fill hose and fill vent hose from
filler neck (Fig. 5).
Fig. 3 Fuel Tank Remove/Install—XJ Models
hose and vent hose to filler neck and tighten clamps. WARNING: W R A P S H O P T O W E L S A R O U N D F U E L
(2) Wrap support straps around tank and over H O S E S TO A B S O R B ANY F U E L S P I L L A G E DURING
studs. Tighten strap nuts to 11.3 N*m (100 in. lbs.) F U E L T A N K REMOVAL.
torque.
(3) Remove transmission jack. (6) Disconnect fuel tank vent hose from vent tube.
(4) Install tank shield. Disconnect fuel supply and return hoses from tubes
(5) If equipped, install tank skid plate. (Fig. 6).
(6) Connect vent hose to vent tube. The fuel tank and skid plate are removed as an as
(7) Connect fuel supply hose to supply tube and sembly.
fuel return hose to return tube. Tighten hose clamps. (7) Centrally position a transmission jack under
(8) Connect fuel pump module wire connector to skid plate/fuel tank assembly.
harness connector. Secure fuel pump module wire (8) Remove skid plate/fuel tank assembly mount
harness to fuel tubes with tie straps. ing nuts (Fig. 7). Do not loosen tank strap nuts.
Fig. 7 Fuel Tank—Remove/Install— YJ Models

(6) Connect fuel supply hose to the supply tube
and fuel return hose to return tube. Tighten hose
clamps.
(7) Install fuel filler neck shroud with push clips.
(8) Lower vehicle.
(9) Fill fuel tank. Install filler cap.
(11) Start vehicle and inspect for leaks.
FUEL GAUGE SENDING UNIT

The fuel gauge sending unit is attached to the fuel
Fig. 6 Fuel Tank Hoses— YJ Models
pump module. Refer to Fuel Pump Module in the
(9) Lower the skid plate/fuel tank assembly Fuel Delivery System section of this group.
slightly and disconnect the gauge sender wire con
nector. F U E L T A N K P R E S S U R E R E L I E F / R O L L O V E R VALVE
(10) Lower the fuel tank on transmission jack. The fuel tank is equipped with a pressure relief/
(11) Remove tank strap nuts to remove tank from rollover valve (Fig. 8). The dual function valve will
skid plate. relieve fuel tank pressure and prevent fuel flow
through the fuel tank vent tubes in the event of ac
INSTALLA TION-* YJ MODELS cidental vehicle rollover.
(1) Place tank into skid plate. Wrap straps around The valve consists of a plunger, spring and orifice/
tank with strap bolts inserted through holes in skid guide plate (Fig. 9). The valve is normally open al
plate. Tighten strap nuts to 7.3 N*m (65 in. lbs.) lowing fuel vapor to vent to the EVAP canister. Here
torque. it is stored until it can be consumed by the engine
(2) Raise skid plate/fuel tank until gauge sender (under controlled conditions). The plunger seats in
wire connector can be connected to harness connec the guide plate at the orifice preventing liquid fuel
tor. from reaching the EVAP canister. This is done if bot
(3) Finish raising skid plate/fuel tank assembly tom of plunger is contacted by fuel sloshing in tank
into position. Tighten mounting nuts to 16 N*m (12 when vehicle is cornering.
ft. lbs.) torque. Remove transmission jack. In the event of accidental vehicle rollover, the
(4) Connect fuel fill hose and fill vent hose to filler valve is inverted. In this position the plunger is
neck. Tighten hose clamps. forced against the guide plate and raw fuel is pre
(5) Connect vent hose to vent tube. vented from flowing through the valve orifice into
the fuel tank vent tube.
PLUNGER
SPRING
J8914-33
Fig. 9 Pressure Relief/Rollover Valve Operation

Fig. 8 Valve Location—Typical
(3) Remove fuel tank. Refer to Fuel Tank Removal.
REMOVAL (4) The rollover valve is seated in a grommet. Re
move by prying one side upward and then roll the
WARNING: T H E FUEL S Y S T E M I S U N t J E R A CON grommet out of tank (Fig. 8).
S T A N T P R E S S U R E (EVEN W I T H T H E ENGINE OFF).
B E F O R E SERVICING T H E P R E S S U R E R E L I E F / INSTALLATION
ROLLOVER VALVE, T H E F U E L S Y S T E M P R E S S U R E (1) Start one side of grommet into opening in fuel
MUST B E RELEASED. R E F E R TO T H E FUEL PRES tank. Using finger pressure only, press valve/grom-
S U R E R E L E A S E P R O C E D U R E IN T H I S G R O U P . met into place.
(2) Install fuel tank. Refer to Fuel Tank Installa
(1) Disconnect negative battery cable. tion.
(2) Remove the fuel filler cap and drain fuel tank. (3) Fill fuel tank. Install fuel tank filler cap.
Refer to Fuel Tank Removal. (4) Connect negative battery cable.
(5) Start vehicle and check for leaks.
14-16 FUEL SYSTEM J
ACCELERATOR PEDAL AND THROTTLE CABLE
GENERAL INFORMATION (3) Before starting engine, operate accelerator
The accelerator pedal is connected to the throttle body pedal to check for any binding.
linkage by the throttle cable. The cable is protected by a THROTTLE CABLE
plastic sheathing and is connected to the throttle body
linkage by a ball socket. It is connected to the upper part REMOVAL
of the accelerator pedal arm by a plastic retainer (clip) (1) From inside the vehicle, hold up accelerator pedal.
(Fig. 1). This retainer (clip) snaps into the top of the ac Remove plastic cable retainer (clip) and throttle cable
celerator pedal arm. Retainer tabs (built into the cable core wire from upper end of accelerator pedal arm (Fig.
sheathing) (Fig. 1) fasten the cable to the dash panel. 1). Plastic cable retainer (clip) snaps into pedal arm,
Dual throttle return springs (attached to the throt (2) Remove the cable core wire at pedal arm.
(3) From inside the vehicle, pinch both sides of the ca
tle shaft) are used to close the throttle.
ble housing retainer tabs (Fig. 1) at the dash panel. Re
CAUTION: Never attempt to remove or alter these springs. move cable housing from dash panel and pull into the
engine compartment.
ACCELERATOR PEDAL (4) Remove cable from clip on the engine cylinder
CAUTION: Be careful not to damage or kink the ca head (valve) cover.
ble core wire (within the cable sheathing) while ser (5) Remove the throttle cable ball end socket at
vicing the accelerator pedal or throttle cable. throttle body linkage (snaps off).
(6) Remove throttle cable from throttle body
REMOVAL mounting bracket by compressing retainer tabs and
(1) From inside the vehicle, hold up accelerator pedal. pushing cable through hole in bracket. Remove throt
Remove plastic cable retainer (clip) and throttle cable tle cable from vehicle.
core wire from upper end of accelerator pedal arm (Fig.
1). Plastic cable retainer (clip) snaps into pedal arm. INSTALLATION
(2) Remove accelerator pedal mounting bracket (1) Slide throttle cable through hole in throttle
nuts. Remove accelerator pedal assembly. body bracket until retainer tabs lock into bracket.
Connect cable ball end to throttle body linkage ball
INSTALLATION (snaps on).
(1) Place accelerator pedal assembly over studs (2) Snap cable into clip on the engine cylinder
protruding from floor pan. Tighten mounting nuts to head (valve) cover.
5 Nmi (36 in. lbs.) torque. (3) Push other end of cable through opening in
(2) Slide throttle cable into opening in top of pedal dash panel until retaining tabs lock into panel.
arm. Push plastic cable retainer (clip) into accelera (4) From inside drivers compartment, slide throttle
tor pedal arm opening until it snaps into place. cable core wire into opening in top of accelerator
pedal arm. Push cable retainer (clip) into pedal arm
opening until it snaps in place.
(5) Before starting engine, operate accelerator
pedal to check for any binding.
Fig. 1 Accelerator Pedal Mounting—Typical Fig. 2 Throttle (Accelerator) Cable—Typical

MPi SYSTEM-COMPONENT DESCRIPTION/SYSTEM OPERATION
INDEX
page page
Air Conditioning (A/C) Clutch Relay-PCM Output . 23 Intake Air Temperature Sensor—PCM Input .... 20
Air Conditioning (A/C) Controls—PCM Input .... 19 Malfunction Indicator Lamp—PCM Output 26
Auto Shut Down (ASD) R e l a y - P C M Output . . . . 24 Manifold Absolute Pressure (MAP) Sensor—
Automatic Shut Down (ASD) S e n s e - P C M Input . 20 PCM Input 21
Ballast Resistor 24 Open Loop/Closed Loop Modes of Operation ... 27
Ballast Resistor Bypass Relay—PCM Output . . . . 25 Overdrive/Override Switch 21
Battery Voltage—PCM Input 20 Oxygen ( 0 ) S e n s o r - P C M Input
2 .... 21
Brake S w i t c h - P C M Input 20 Park/Neutral S w i t c h - P C M Input 22
Camshaft Position Sensor—PCM Input ........ 20 Power Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankshaft Position Sensor—PCM Input 21 Power Steering Pressure Switch—PCM Input ... 22
E M R L a m p - P C M Output 24 Powertrain Control Module (PCM) 18
Engine Coolant Temperature Sensor—PCM Input . 21 Radiator Fan Relay—PCM Output 26
Fuel Injectors-PCM Output 25 SCI Receive-PCM Input 22
Fuel Pressure Regulator 30 SCI T r a n s m i t - P C M Output 27
Fuel Pump Relay—PCM Output 24 Sensor Return —PCM Input 23
Fuel Rail 30 Shift Indicator—PCM Output ................ 27
General Information . 17 Speed Control-PCM Input 22
Generator F i e l d - P C M Output 25 Speed Control-PCM Output . 27
Generator Lamp—PCM Output .............. 25 Tachometer—PCM Output . . . . . . . . . . . . . . . . . . 27
Idle Air Control (IAC) Motor—PCM Output 26 Throttle Body 29
Ignition Circuit Sense—PCM Input 21 Throttle Position Sensor ( T P S ) - P C M Input . . . . . 23
Ignition C o i l - P C M Output 26 Vehicle Speed Sensor—PCM Input 23
GENERAL INFORMATION an air/fuel ratio of 14.7 to 1 by constantly adjusting

All 2.5L 4 cylinder and 4 . 0 L 6 cylinder engines are injector pulse width. Injector pulse width is the
equipped with sequential Multi-Port Fuel Injection length of time that the injector opens and sprays fuel
(MPI). The MPI system (Fig. 1) provides precise air/ into the chamber. The PCM adjusts injector pulse
fuel ratios for all driving conditions. width by opening and closing the ground path to the
The Powertrain Control Module (PCM) operates injector.
the fuel system. The PCM was formerly referred to Manifold absolute pressure (air density) and engine
as the SBEC or engine controller. The PCM is a pre rpm (speed) are the primary inputs that determine
programmed, dual microprocessor digital computer. fuel injector pulse width. The PCM also monitors
It regulates ignition timing, air-fuel ratio, emission other inputs when adjusting air-fuel ratio.
control devices, charging system, speed control, air Inputs That Effect Fuel Injector Pulse Width
conditioning compressor clutch engagement and idle • Exhaust gas oxygen content
speed. The PCM can adapt its programming to meet • Coolant temperature
changing operating conditions. • Manifold absolute pressure (MAP)
Powertrain Control Module (PCM) Inputs rep • Engine speed
resent the instantaneous engine operating conditions. • Throttle position
Air-fuel mixture and ignition timing calibrations for • Battery voltage
various driving and atmospheric conditions are pre • Air conditioning selection
programmed into the PCM. The PCM monitors and • Transmission gear selection (automatic transmis
analyzes various inputs. It then computes engine fuel sions only)
and ignition timing requirements based on these in • Speed control
puts. Fuel delivery control and ignition timing will The powertrain control module (PCM) adjusts igni
then be adjusted accordingly. tion timing by controlling ignition coil operation. The
Other inputs to the PCM are provided by the brake ignition coil receives battery voltage when the igni
light switch, air conditioning select switch and the tion key is in the run or starter position. The PCM
speed control switches. All inputs to the PCM are provides a ground for the ignition coil. The coil dis
converted into signals. charges when the PCM supplies a ground. By switch
Electrically operated fuel injectors spray fuel in ing the ground path on and off, the PCM regulates
precise metered amounts into the intake port directly ignition timing.
above the intake valve. The injectors are fired in a The sensors and switches that provide inputs to the
specific sequence by the PCM. The PCM maintains powertrain control module (PCM) comprise the En-
INPUTS OUTPUTS
DRB II
POWERTRAIN CONTROL SCAN T O O L
MODULE
SPEED
CONTROL
PARK/NEUTRAL
TORQUE CONVERTER
A/C L O W SWITCH CLUTCH SOLENOID
P R E S S U R E CUTOFF
SWITCH VEHICLE
SPEED S E N S O R
A/C CLUTCH AUTO SHUTDOWN OVERDRIVE

RELAY RELAY SOLENOID
ENGINE
COOLANT BATTERY
TEMPERATURE
SENSOR MAP SENSOR SPEED SHIFT
CONTROL INDICATOR
IDLE AIR LAMP
t—r CONTROL MOTOR EMISSION

CONTROL SOLENOIDS
CHARGE AIR
AIR CHARGE
TEMPERATURE
SENSOR TEMPERATURE
SENSOR
PARK THROTTLE
DISTRIBUTOR IGNITION COIL
SOLENOID
W I T H CAMSHAFT
POSITION
GENERATOR
SENSOR OVERDRIVE ASD
OVERRIDE SENSE FUEL
SWITCH INJECTORS FUEL
CRANKSHAFT PUMP
RELAY
POSITION
J9314-117
CCMCrtD
Fig. 1 MPI Components—Typical

gine Control System. It is also comprised of the PCM On XJ models, the PCM is located in the engine
Outputs (engine control devices that the are operated compartment next to the air cleaner (Fig. 2 ) . On YJ
by the PCM). models, the PCM is located in the engine compart
ment behind the windshield washer fluid reservoir
SYSTEM DIAGNOSIS (Fig. 3).
The Powertrain Control Module (PCM) tests many
of its own input and output circuits. If a Diagnostic
Trouble Code (DTC) is found in a major system, this
information is stored in the PCM memory. Refer to
On-Board Diagnostics in the MPI System—General
Diagnosis section of this group for DTC information.

The Powertrain Control Module (PCM) operates
the fuel system. The PCM was formerly referred to
as the SBEC or engine controller. The PCM is a pre
programmed, dual microprocessor digital computer.
It regulates ignition timing, air-fuel ratio, emission
control devices, charging system, speed control, air
conditioning compressor clutch engagement and idle
speed. The PCM can adapt its programming to meet
changing operating conditions. Fig. 2 PCM Location—XJ Models
FUEL SYSTEM 14 - 1S
J • Speed control resume switch
• Speed control set switch
• Speed control on/off switch
• Camshaft position sensor signal
• Throttle position sensor
• Vehicle speed sensor
• Sensor return
• Power ground
• Signal ground
Powertrain Control Module (PCM) Outputs
• A/C clutch relay
• Idle air control (IAC) motor
• Auto shut down (ASD) relay
• Generator field
• Malfunction indicator lamp
• Fuel injectors
Fig. 3 PCM Location— YJ Models • Fuel pump relay
The PCM receives input signals from various • Ignition coil
switches and sensors. Based on these inputs, the • SCI transmit (DRB II connection)
PCM regulates various engine and vehicle operations • Shift indicator lamp (manual transmission only)
through different system components. These compo • Speed control vacuum solenoid
nents are referred to as Powertrain Control Module • Speed control vent solenoid
(PCM) Outputs. The sensors and switches that pro • Tachometer (on instrument panel, if equipped)
vide inputs to the PCM are considered Powertrain The powertrain control module (PCM) contains a
Control Module (PCM) Inputs. voltage convertor. This converts battery voltage to a
regulated 8.0 volts. It is used to power the crankshaft
The PCM adjusts ignition timing based upon in position sensor and camshaft position sensor. The
puts it receives from sensors that react to: engine PCM also provides a five (5) volt supply for the Man
rpm, manifold absolute pressure, coolant tempera ifold Absolute Pressure (MAP) sensor and Throttle
ture, throttle position, transmission gear selection Position Sensor (TPS).
(automatic transmission), vehicle speed and the
brake switch. AIR CONDITIONING (A/C) C 0 N T R 0 L S - P C M INPUT
The PCM adjusts idle speed based on inputs it re The A/C control system information applies to fac
ceives from sensors that react to: throttle position, tory installed air conditioning units.
vehicle speed, transmission gear selection, coolant A/C SELECT SIGNAL: When the A/C switch is
temperature and from inputs it receives from the air in the ON position and the A/C low pressure switch
conditioning clutch switch and brake switch. is closed, an input signal is sent to the powertrain
Based on inputs that it receives, the PCM adjusts control module (PCM). The signal informs the PCM
ignition coil dwell. The PCM also adjusts the gener that the A/C has been selected. The PCM adjusts idle
ator charge rate through control of the generator speed to a pre-programmed rpm through the idle air
field and provides speed control operation. control (IAC) motor to compensate for increased en
Powertrain Control Module (PCM) Inputs: gine load.
• Generator output A/C REQUEST SIGNAL: Once A/C has been se
• A/C request (if equipped with factory A/C) lected, the powertrain control module (PCM) receives
• A/C select (if equipped with factory A/C) the A/C request signal from the evaporator switch.
• Auto shut down (ASD) sense The input indicates that the evaporator temperature
• Intake air temperature sensor is in the proper range for A/C application. The PCM
• Battery voltage uses this input to cycle the A/C compressor clutch
• Brake switch (through the A/C relay). It will also determine the
• Coolant temperature sensor correct engine idle speed through the idle air control
• Crankshaft position sensor (IAC) motor position.
• Ignition circuit sense (ignition switch in run posi If the A/C low pressure switch opens (indicating a
tion) low refrigerant level), the PCM will not receive an
• Manifold absolute pressure sensor A/C select signal. The PCM will then remove the
• Overdrive/override switch ground from the A/C relay. This will deactivate the
• Oxygen sensor A/C compressor clutch.
• Park/neutral switch (auto, trans, only) If the evaporator switch opens, (indicating that
• SCI receive (DRB II connection) evaporator is not in proper temperature range), the
PCM will not receive the A/C request signal. The 9 O'CLOCK CAMSHAFT POSITION
PCM will then remove the ground from the A/C re
lay, deactivating the A/C compressor clutch.
AUTOMATIC SHUT DOWN (ASD) S E N S E - P C M

INPUT
A 12 volt signal at this input indicates to the PCM
that the ASD has been activated. The ASD relay is
located in the Power Distribution Center (PDC) in
the engine compartment. It is used to connect oxygen
sensor heater element, ignition coil, generator field
winding and fuel injectors to 12 volt + power supply.
This input is used only to sense that the ASD relay
is energized. If the powertrain control module (PCM)
does not see 12 volts at this input when the ASD
should be activated, it will set a Diagnostic Trouble
Code (DTC).
BATTERY VOLTAGE—PCM INPUT

The battery voltage input provides power to the
powertrain control module (PCM). It also informs the ROTOR J938D-8
PCM what voltage level is supplied to the ignition Fig. 4 Camshaft Position Sensor
coil and fuel injectors.
If battery voltage is low, the PCM will increase injec
tor pulse width (period of time that the injector is ener
gized). This is done to compensate for the reduced flow
through injector caused by the lowered voltage.
BRAKE S W I T C H — P C I 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. After
receiving this input, the PCM maintains idle speed
to a scheduled rpm through control of the idle air
control (IAC) motor. The brake switch input is also
used to operate the speed control system.
CAMSHAFT POSITION S E N S O R - P C M INPUT

A sync signal is provided by the camshaft position
sensor located in the ignition distributor (Fig. 4). The Fig. 5 Sensor Location—4.0L Engine
sync signal from this sensor works in conjunction with
the crankshaft position sensor to provide the powertrain
control module (PCM) with inputs. This is done to es
tablish and maintain correct injector firing order.
Refer to Camshaft Position Sensor in Group 8 D , Ig
nition System for more information.
INTAKE A I R T E M P E R A T U R E S E N S O R - P C M I N P U T
The intake manifold air temperature sensor is in
stalled in the intake manifold with the sensor ele
ment extending into the air stream (Figs. 5 or 6).
The sensor provides an input voltage to the power-
train control module (PCM) indicating intake mani
fold air temperature. The input is used along with
inputs from other sensors to determine injector pulse
width. As the temperature of the air-fuel stream in
the manifold varies, the sensor resistance changes.
This results in a different input voltage to the PCM. Fig. 6 Sensor Location—2.5L Engine
J FUEL SYSTEM 14-21
CRANKSHAFT POSITION S E N S O R - P C M INPUT MANIFOLD ABSOLUTE PRESSURE (MAP)

This sensor is a Hall Effect device that detects S E N S O R - P C M INPUT
notches in the flywheel (manual transmission), or The MAP sensor reacts to absolute pressure in the
flexplate (automatic transmission). intake manifold. It provides an input voltage to the
This sensor is used to indicate to the powertrain powertrain control module (PCM). As engine load
control module (PCM) that a spark and or fuel injec changes, manifold pressure varies. The change in
tion event is to be required. The output from this manifold pressure causes MAP sensor voltage to
sensor, in conjunction with the camshaft position change. The change in MAP sensor voltage results in
sensor signal, is used to differentiate between fuel in a different input voltage to the PCM. The input volt
jection and spark events. It is also used to synchro age level supplies the PCM with information about
nize the fuel injectors with their respective cylinders. ambient barometric pressure during engine start-up
Refer to Group 8D, Ignition System for more crank (cranking) and engine load while the engine is run
shaft position sensor information. ning. The PCM uses this input along with inputs
The engine will not operate if the PCM does not re from other sensors to adjust air-fuel mixture.
ceive a crankshaft position sensor input. The MAP sensor is mounted on the dash panel.
The sensor is connected to the throttle body with a
ENGINE COOLANT TEMPERATURE S E N S O R - P C M vacuum hose and to the PCM electrically.
INPUT
The coolant temperature sensor is installed in the OVERDRIVE/OVERRIDE SWITCH
thermostat housing (Fig. 7) and protrudes into the On vehicles equipped with overdrive, the power-
water jacket. The sensor provides an input voltage to train control module (PCM) regulates the 3 - 4 over
the powertrain control module (PCM) relating cool drive up-shift and down-shift through the overdrive
ant temperature. The PCM uses this input along solenoid.
with inputs from other sensors to determine injector Refer to Group 21 for more information.
pulse width and ignition timing. As coolant temper
ature varies, the coolant temperature sensor's resis OXYGEN (0 ) S E N S O R - P C M INPUT
2
tance changes. The change in resistance results in a The 0 sensor is located in the exhaust down pipe
2
different input voltage to the PCM. (Fig. 8). It provides an input voltage to the power-
When the engine is cold, the PCM will operate in train control module (PCM) relating the oxygen con
Open Loop cycle. It will demand slightly richer air- tent of the exhaust gas. The PCM uses this
fuel mixtures and higher idle speeds. This is done information to fine tune the air-fuel ratio by adjust
until normal operating temperatures are reached. ing injector pulse width.
Refer to Open Loop/Closed Loop Modes of Opera The 0 sensor produces voltages from 0 to 1 volt.
2
tion in this section of the group for more information. This voltage will depend upon the oxygen content of
the exhaust gas in the exhaust manifold. When a
large amount of oxygen is present (caused by a lean
air-fuel mixture), the sensor produces a low voltage.
When there is a lesser amount present (rich air-fuel
mixture) it produces a higher voltage. By monitoring
the oxygen content and converting it to electrical
voltage, the sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heating ele
ment that keeps the sensor at proper operating tem
perature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
In Closed Loop operation, the powertrain control
module (PCM) monitors the 0 sensor input (along
2
with other inputs). It then adjusts the injector pulse

width accordingly. During Open Loop operation, the
Fig. 7 Coolant Temperature Sensor—Typical PCM ignores the 0 sensor input and adjusts injector
2
IGNITION CIRCUIT S E N S E - P C M INPUT pulse width to a preprogrammed value (based on

The ignition circuit sense input tells the power- other sensor inputs).
train control module (PCM) the ignition switch has
energized the ignition circuit. Refer to the wiring di
agrams for circuit information.
14-22 FUEL SYSTEM J
Fig. 8 Heated Oxygen Sensor Location—Typical Fig. 9 Power Steering Pump Pressure Switch—YJ
Models
PARK/NEUTRAL S W I T C H - P C M INPUT
The park/neutral switch is located on the transmis
sion housing and provides an input to the powertrain
control module (PCM). This will indicate that the au
tomatic transmission is in Park, Neutral or a drive
gear selection. This input is used to determine idle
speed (varying with gear selection), fuel injector
pulse width and ignition timing advance. Refer to
Group 21, Transmissions, for testing, replacement
and adjustment information.
P O W E R GROUND
The power ground is used to control ground circuits
for the following powertrain control module (PCM)
loads:
• Generator Field Winding
• 8 volt (PCM) power supply
• Fuel Injectors Fig. 10 Power Steering Pump Pressure Switch—XJ
• Ignition Coil Models
control module (PCM) receives data from the DRB II
POWER STEERING PRESSURE SWITCH -PCM
INPUT through the SCI Receive circuit.
A pressure sensing switch is included in the power
steering system (mounted on the high-pressure line). SPEED C 0 N T R 0 L - P C M INPUT
This switch will be on vehicles equipped with a 2.5L The speed control system provides three separate
engine and power steering. The switch (Fig. 9 YJ inputs to the powertrain control module (PCM); On/
Models or Fig. 10 XJ Models) provides an input to Off, Set and Resume. The On/Off input informs the
the PCM. This input is provided during periods of PCM that the speed control system has been acti
high pump load and low engine rpm; such as during vated. The Set input informs the PCM that a fixed
parking maneuvers. The PCM will then increase the vehicle speed has been selected. The Resume input
idle speed through the idle air control (IAC) motor. indicates to the PCM that the previous fixed speed is
This is done to prevent the engine from stalling un requested.
der the increased load. The speed control operating range is from 5 0 km/h
When steering pump pressure exceeds 1896 kPa ± to 1 4 2 km/h ( 3 5 to 8 5 mph). Inputs that effect speed
172 kPa (275 ± 25 psi) the PCM will increase the en control operation are:
gine idle speed. This will prevent the engine from • Park/neutral switch
stalling. • Vehicle speed sensor
• Throttle position sensor
SCI RECEIVE-PCM INPUT Refer to Group 8H for further speed control infor
SCI Receive is the serial data communication re mation.
ceive circuit for the DRB II scan tool. The powertrain
J FUEL SYSTEM 1 4 - 2 3
SENSOR RETURN—PCM INPUT

Sensor Return provides a low noise ground refer
ence for all system sensors.
THROTTLE POSITION SENSOR (TPS)-PCM INPUT

The Throttle Position Sensor (TPS) is mounted on
the throttle body (Figs. 11 or 12). The TPS is a vari
able resistor that provides the powertrain control
module (PCM) with an input signal (voltage) that
represents throttle blade position. The sensor is con
nected to the throttle blade shaft. As the position of
the throttle blade changes, the resistance of the TPS
changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the TPS. Fig. 12 Throttle Position Sensor—4.0L Engine
This will vary in an approximate range of from 1 Under deceleration conditions, the PCM adjusts the
volt at minimum throttle opening (idle), to 4 volts at idle air control (IAC) motor to maintain a desired
wide open throttle. Along with inputs from other sen MAP value. Under idle conditions, the PCM adjusts
sors, the PCM uses the TPS input to determine cur the IAC motor to maintain a desired engine speed.
rent engine operating conditions. In response to
engine operating conditions, the PCM will adjust fuel
injector pulse width and ignition timing.
Fig. 13 Vehicle Speed Sensor—Typical

AIR CONDITIONING (A/C) CLUTCH RELAY-PCM
OUTPUT
Fig. 11 Throttle Position Sensor—2.5L Engine
The powertrain control module (PCM) activates the
VEHICLE SPEED SENSOR-PCM INPUT A/C compressor through the A/C clutch relay. The
The speed sensor (Fig. 13) is located in the exten PCM regulates A/C compressor operation by switch
sion housing of the transmission (2WD) or on the ing the ground circuit for the A/C clutch relay on
transfer case extension housing (4WD). The sensor and off. The relay is located in the Power Distribu
input is used by the powertrain control module tion Center (PDC) (Figs. 14 or 15). For the location of
(PCM) to determine vehicle speed and distance trav the relay within the PDC, refer to label under PDC
eled. cover.
The speed sensor generates 8 pulses per sensor rev When the PCM receives a request for A/C from A/C
olution. These signals, in conjunction with a closed evaporator switch, it will adjust idle air control (IAC)
throttle signal from the throttle position sensor, indi motor position. This is done to increase idle speed.
cate a closed throttle deceleration to the PCM. When The PCM will then activate the A/C clutch through
the vehicle is stopped at idle, a closed throttle signal the A/C clutch relay. The PCM adjusts idle air con
is received by the PCM (but a speed sensor signal is trol (IAC) stepper motor position to compensate for
not received). increased engine load from the A/C compressor.
the powertrain control module (PCM). The PCM op

erates the relay by switching the ground circuit on
and off.
The fuel pump relay is controlled by the PCM
through same circuit that the ASD relay is con
trolled.
EMR L A M P - P C M OUTPUT
The EMR lamp is not used for the 1993 model
year.
FUEL PUMP R E L A Y - P C M OUTPUT

The PCM energizes the fuel pump through the fuel
pump relay. Battery voltage is applied to the relay
a ground is provided by the PCM.
Fig. 14 Power Distribution Center—YJ Models • YJ Models: The PCM operates the fuel pump
through the fuel pump relay during all operating
conditions.
• XJ Models: The PCM operates the fuel pump
through the fuel pump relay and ballast resistor ex
cept for wide open throttle or heavy load conditions.
Refer to Ballast Resistor (XJ Models Only) or Ballast
Resistor Bypass Relay—PCM Output for additional
information.
On YJ models the relay is located in the Power
Distribution Center (PDC) next to the battery (Fig.
14). On XJ models the relay is located in the PDC
next to the coolant recovery bottle (Fig. 15).
BALLAST RESISTOR
J9114-91
MJ MODELS ONLY
Fig. 15 Power Distribution Center—XJ Models A ballast resistor is installed in-line between the
By switching the ground path for the relay on and relay and the fuel pump (Fig. 16). The PCM nor
off, the PCM is able to cycle the A/C compressor mally operates the fuel pump through the fuel pump
clutch. This is based on changes in engine operating relay and ballast resistor during all operating condi
conditions. If, during A/C operation, the PCM senses tions. This will be except for wide open throttle
low idle speeds or a wide open throttle condition, it (WOT) and high engine loads. The ballast resistor re
will de-energize the relay. This prevents A/C clutch duces voltage to the fuel pump, reducing the level of
engagement. The relay will remain de-energized un fuel pump noise.
til the idle speed increases or the wide open throttle When the ballast resistor bypass relay is energized,
condition exceeds 15 seconds or no longer exists. The voltage is applied to the fuel pump through the bal
PCM will also de-energize the relay if coolant tem last resistor (voltage to fuel pump is reduced). Dur
perature exceeds 125°C (257°F). ing WOT and high load operation, the ballast
resistor bypass relay is de-energized and the ballast
AUTO SHUT DOWN (ASD) RELAY—PCM OUTPUT resistor is bypassed (full battery voltage is supplied
The ASD relay is located in the Power Distribution to fuel pump). Also refer to Ballast Resistor Bypass
Center (PDC) (Figs. 14 or 15). For the location of this Relay-PCM Output. Refer to Group 8W, Wiring Di
relay within the PDC, refer to label under PDC agrams for circuit layout.
cover.
The ASD supplies battery voltage to the fuel pump,
fuel injector, ignition coil, generator field winding
and oxygen ( 0 ) sensor heating element. The ground
2
circuit for the coil in the ASD relay is controlled by

FUEL SYSTEM 14 - 25
FUEL I N J E C T O R S - P C M OUTPUT
Six individual fuel injectors are used with the 4.0L
6 cylinder engine. Four individual fuel injectors are
used with the 2.5L 4 cylinder engine. The injectors
are attached to the fuel rail (Fig. 18).
The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the in
take valve ports of the cylinder head. The engine
wiring harness connector for each fuel injector is
equipped with an attached numerical tag (INJ 1, INJ
2 etc.). This is used to identify each fuel injector.
The injectors are energized individually in a se
quential order by the powertrain control module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
Fig. 16 Ballast Resistor—XJ Models Only that the injector is energized. The PCM will adjust
BALLAST RESISTOR BYPASS R E L A Y - P C M injector pulse width based on various inputs it re
OUTPUT ceives.
During start up, battery voltage is supplied to the
XJ MODELS ONLY injectors through the ASD relay. When the engine is
Voltage is normally supplied to the fuel pump operating, voltage is supplied by the charging sys
through the fuel pump relay and reduced by the bal tem. The PCM determines injector pulse width based
last resistor, except during heavy load or wide open on various inputs.
throttle (WOT) conditions.
During heavy load or wide open throttle conditions,
full battery voltage is supplied to the fuel pump
through the ballast resistor bypass relay.
The ballast resistor bypass relay is controlled by
the Powertrain Control Module (PCM).
The PCM energizes the ballast resistor bypass re
lay by switching the ground circuit to the relay (on-
and-off). Battery voltage for the bypass relay is
supplied through the fuel pump relay.
The ballast resistor bypass relay is located on a
bracket connected to the Power Distribution Center
(PDC) (Fig. 17).
Fig. 18 Fuel Injectors—Typical

GENERATOR F I E L D - P C M OUTPUT
The powertrain control module (PCM) regulates
the charging system voltage within a range of 12.9 to
15.0 volts. Refer to Group 8A for charging system in
formation.
GENERATOR L A M P - P C M OUTPUT
IF EQUIPPED
If the powertrain control module (PCM) senses a
low charging condition in the charging system, it
will illuminate the generator lamp on the instrument
Fig. 17 Bypass Relay—XJ Models Only panel. For example, during low idle with all accesso
ries turned on, the light may momentarily go on.
Once the PCM corrects idle speed to a higher rpm,
the light will go out. Refer to Group 8A, Battery/ IGNITION COIL-PGM OUTPUT
Starting/Charging Systems for charging system in System voltage is supplied to the ignition coil pos
formation. itive terminal. The powertrain control module (PCM)
operates the ignition coil. Base (initial) ignition
IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT timing is not adjustable. The PCM adjusts ignition
The IAC motor is mounted on the throttle body timing to meet changing engine operating conditions.
(Figs. 19 or 2 0 ) and is controlled by the powertrain The ignition coil is located near the ignition dis
control module (PCM). tributor (Fig. 21).
Refer to Group 8D, Ignition System for additional
information.
fJ?1,14-8^
Fig. 21 Ignition Coil—Typical

INTAKE MANIFOLD CHARGE
INTAKE
MALFUNCTION INDICATOR LAMP-PCM OUTPUT
AIR TEMP. S E N S O R
VNIFQLD The Malfunction Indicator Lamp (formerly referred
to as the Check Engine Lamp) illuminates on the in
strument panel each time the ignition key is turned
on. It will stay on for three seconds as a bulb test.
If the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
THROTTLE is a warning that the PCM has recorded a system or
POSITION sensor malfunction. In some cases, when a problem is
SENSOR declared, the PCM will go into a limp-in mode. This
J9314-140 is an attempt to keep the system operating. It signals
an immediate need for service.
Fig. 20 IAC Motor—2.5L Engine The lamp can also be used to display a Diagnostic
The throttle body has an air control passage that Trouble Code (DTC). Cycle the ignition switch On-
provides air for the engine at idle (the throttle plate Off-On-Off-On within three seconds and any codes
is closed). The IAC motor pintle protrudes into the stored in the PCM memory will be displayed. This is
air control passage and regulates air flow through it. done in a series of flashes representing digits. Refer
Based on various sensor inputs, the powertrain con to On-Board Diagnostics in the General Diagnosis
trol module (PCM) adjusts engine idle speed by mov section of this group for more information.
ing the IAC motor pintle in and out of the air control
RADIATOR FAN RELAY—PCM OUTPUT
passage. The IAC motor is positioned when the igni
tion key is turned to the On position. XJ MODELS ONLY
A (factory adjusted) set screw is used to mechani The electric fan used in XJ models (equipped with
cally limit the position of the throttle body throttle 4.0L engine, heavy duty cooling and/or air condition
plate. Never attempt to adjust the engine idle ing) is controlled by the PCM through radiator fan
speed using this screw. All idle speed functions are relay. The relay is energized when coolant tempera
controlled by the PCM. ture is above 103°C (217°F). It will then de-energize
when coolant temperature drops to 98°C (208°F). Re only according to preset PCM programming. Input
fer to Group 7, Cooling Systems for more informa from the oxygen ( 0 ) sensor is not monitored during
2
tion. Open Loop modes.

During Closed Loop modes, the PCM will monitor
SCI TRANSMIT—PCM OUTPUT the oxygen ( 0 ) sensor input. This input indicates to
2
SCI Transmit is the serial data communication the PCM whether or not the calculated injector pulse
transmit circuit for the DRB II scan tool. The power- width results in the ideal air-fuel ratio. This ratio is
train control module (PCM) transmits data to the 14.7 parts air-to-1 part fuel. By monitoring the ex
DRB II through the SCI Transmit circuit. haust oxygen content through the 0 sensor, the
2
PCM can fine tune the injector pulse width. This is

SHIFT I N D I C A T O R - P C M OUTPUT done to achieve optimum fuel economy combined
Vehicles equipped with manual transmissions have with low emission engine performance.
an Up-Shift indicator lamp. The lamp is controlled The fuel injection system has the following modes
by the powertrain control module (PCM). The lamp of operation:
illuminates on the instrument panel to indicate when • Ignition switch ON
the driver should shift to the next highest gear for • Engine start-up (crank)
best fuel economy. The PCM will turn the lamp OFF • Engine warm-up
after 3 to 5 seconds if the shift of gears is not per • Idle
formed. The up-shift light will remain off until vehi • Cruise
cle stops accelerating and is brought back to range of • Acceleration
up-shift light operation. This will also happen if ve • Deceleration
hicle is shifted into fifth gear. • Wide open throttle (WOT)
The indicator lamp is normally illuminated when • Ignition switch OFF
the ignition switch is turned on and it is turned off The ignition switch On, engine start-up (crank),
when the engine is started up. With the engine run engine warm-up, acceleration, deceleration and wide
ning, the lamp is turned on/off depending upon en open throttle modes are Open Loop modes. The idle
gine speed and load. and cruise modes, (with the engine at operating tem
perature) are Closed Loop modes.
SPEED CONTROL-PCM OUTPUT
Speed control operation is regulated by the power- IGNITION SWITCH (KEY-ON) MODE
train control module (PCM). The PCM controls the This is an Open Loop mode. When the fuel system
vacuum to the throttle actuator through the speed is activated by the ignition switch, the following ac
control vacuum and vent solenoids. Refer to Group tions occur:
8H for speed control information. • The powertrain control module (PCM) pre-posi-
tions the idle air control (IAC) motor.
TACHOMETER—PCM OUTPUT
• The PCM determines atmospheric air pressure
The powertrain control module (PCM) supplies en
from the MAP sensor input to determine basic fuel
gine rpm values to the instrument cluster tachome
strategy.
ter (if equipped). Refer to Group 8E for tachometer
• The PCM monitors the engine coolant temperature
information.
sensor input. The PCM modifies fuel strategy based
OPEN LOOP/CLOSED LOOP MODES OF on this input.
OPERATION • Intake manifold air temperature sensor input is
As input signals to the powertrain control module monitored
(PCM) change, the PCM adjusts its response to the • Throttle position sensor (TPS) is monitored
output devices. For example, the PCM must calculate • The auto shut down (ASD) relay is energized by
different injector pulse width and ignition timing for the PCM for approximately three seconds.
idle than it does for wide open throttle (WOT). There • XJ Models: The fuel pump is energized through
are several different modes of operation that deter the fuel pump relay and ballast resistor by the PCM.
mine how the PCM responds to the various input sig The fuel pump will operate for approximately one
nals. second unless the engine is operating or the starter
motor is engaged
MODES • YJ Models: The fuel pump is energized through
• Open Loop the fuel pump relay by the PCM. The fuel pump will
• Closed Loop operate for approximately one second unless the en
During Open Loop modes, the powertrain control gine is operating or the starter motor is engaged.
module (PCM) receives input signals and responds
• The 0 sensor heater element is energized through

2
• The PCM operates the A/C compressor clutch
the fuel pump relay. The 0 sensor input is not used
2
through the clutch relay. This is done if A/C has
by the PCM to calibrate air-fuel ratio during this been selected by the vehicle operator and requested
mode of operation. by the A/C thermostat.
• The up-shift indicator light is illuminated (manual • If the vehicle has a manual transmission, the up
transmission only). shift light is operated by the PCM.
• When engine has reached operating temperature,
ENGINE START-UP MODE the PCM will begin monitoring 0 sensor input. The
2
This is an Open Loop mode. The following actions system will then leave the warm-up mode and go
occur when the starter motor is engaged. into closed loop operation.
The powertrain control module (PCM) receives in
puts from: IDLE MODE
• Battery voltage When the engine is at operating temperature, this
• Engine coolant temperature sensor is a Closed Loop mode. At idle speed, the powertrain
• Crankshaft position sensor control module (PCM) receives inputs from:
• Intake manifold air temperature sensor • Air conditioning select signal (if equipped)
• Manifold absolute pressure (MAP) sensor • Air conditioning request signal (if equipped)
• Throttle position sensor (TPS) • Battery voltage
• Starter motor relay • Crankshaft position sensor
• Camshaft position sensor signal • Engine coolant temperature sensor
The PCM monitors the crankshaft position sensor. • Intake manifold air temperature sensor
If the PCM does not receive a crankshaft position • Manifold absolute pressure (MAP) sensor
sensor signal within 3 seconds of cranking the en • Throttle position sensor (TPS)
gine, it will shut down the fuel injection system. • Camshaft position sensor signal (in the distributor)
The fuel pump is activated by the PCM through • Battery voltage
the fuel pump relay. • Park/Neutral Switch (Gear indicator signal—Auto,
Voltage is applied to the fuel injectors with the trans, only)
PCM. The PCM will then control the injection se • Oxygen sensor
quence and injector pulse width by turning the Based on these inputs, the following occurs:
ground circuit to each individual injector on and off. • Voltage is applied to the fuel injectors with the
The PCM determines the proper ignition timing ac powertrain control module (PCM). The PCM will
cording to input received from the crankshaft posi then control injection sequence and injector pulse
tion sensor. width by turning the ground circuit to each individ
ual injector on and off.
ENGINE WARM-UP MODE • The PCM monitors the 0 sensor input and adjusts
2
This is an Open Loop mode. During engine warm- air-fuel ratio by varying injector pulse width. It also
up, the powertrain control module (PCM) receives in adjusts engine idle speed through the idle air control
puts from: (IAC) motor.
• Battery voltage • The PCM adjusts ignition timing by increasing
• Crankshaft position sensor and decreasing spark advance.
• Engine coolant temperature sensor • The PCM operates the A/C compressor clutch
• Intake manifold air temperature sensor through the clutch relay. This happens if A/C has
• Manifold absolute pressure (MAP) sensor been selected by the vehicle operator and requested
• Throttle position sensor (TPS) by the A/C thermostat.
• Camshaft position sensor signal (in the distributor)
• Park/Neutral Switch (Gear indicator signal—auto, CRUISE MODE
trans, only) When the engine is at operating temperature, this
• Air conditioning select signal (if equipped) is a Closed Loop mode. At cruising speed, the power-
• Air conditioning request signal (if equipped) train control module (PCM) receives inputs from:
Based on these inputs the following occurs: • Air conditioning select signal (if equipped)
• Voltage is applied to the fuel injectors with the • Air conditioning request signal (if equipped)
powertrain control module (PCM). The PCM will • Battery voltage
then control the injection sequence and injector pulse • Engine coolant temperature sensor
width by turning the ground circuit to each individ • Crankshaft position sensor
ual injector on and off. • Intake manifold air temperature sensor
• The PCM adjusts engine idle speed through the • Manifold absolute pressure (MAP) sensor
idle air control (IAC) motor and adjusts ignition tim • Throttle position sensor (TPS)
ing. • Camshaft position sensor signal (in the distributor)
J FUEL SYSTEM 14-29
• Park/Neutral switch (gear indicator signal—auto, WIDE OPEN THROTTLE MODE

trans, only) This is an Open Loop mode. During wide open
• Oxygen ( 0 ) sensor
2
throttle operation, the powertrain control module
Based on these inputs, the following occurs: (PCM) receives the following inputs.
• Voltage is applied to the fuel injectors with the • Battery voltage
PCM. The PCM will then adjust the injector pulse • Crankshaft position sensor
width by turning the ground circuit to each individ • Engine coolant temperature sensor
ual injector on and off. • Intake manifold air temperature sensor
• The PCM monitors the 0 sensor input and adjusts
2 • Manifold absolute pressure (MAP) sensor
air-fuel ratio. It also adjusts engine idle speed • Throttle position sensor (TPS)
through the idle air control (IAC) motor. • Camshaft position sensor signal (in the distributor)
• The PCM adjusts ignition timing by turning the During wide open throttle conditions, the following
ground path to the coil on and off. occurs:
• The PCM operates the A/C compressor clutch • The ballast resistor is bypassed and full system
through the clutch relay. This happens if A/C has voltage is applied to the fuel pump. This is done
been selected by the vehicle operator and requested through the ballast resistor bypass relay (XJ models
by the A/C thermostat. only)
ACCELERATION MODE • Voltage is applied to the fuel injectors with the
This is an Open Loop mode. The powertrain control powertrain control module (PCM). The PCM will
module (PCM) recognizes an abrupt increase in then control the injection sequence and injector pulse
throttle position or MAP pressure as a demand for width by turning the ground circuit to each individ
increased engine output and vehicle acceleration. ual injector on and off. The PCM ignores the oxygen
The PCM increases injector pulse width in response sensor input signal and provides a predetermined
to increased throttle opening. amount of additional fuel. This is done by adjusting
injector pulse width.
DECELERATION MODE • The PCM adjusts ignition timing by turning the
When the engine is at operating temperature, this ground path to the coil on and off.
is an Open Loop mode. During hard deceleration, the • The PCM opens the ground circuit to the A/C
powertrain control module (PCM) receives the follow clutch relay to disengage the A/C compressor clutch.
ing inputs. This will be done for approximately 15 seconds (if the
• Air conditioning select signal (if equipped) air conditioning system is operating).
• Air conditioning request signal (if equipped) If the vehicle has a manual transmission, the up
• Battery voltage shift light is operated by the PCM.
• Engine coolant temperature sensor
• Crankshaft position sensor IGNITION SWITCH OFF MODE
• Intake manifold air temperature sensor When ignition switch is turned to OFF position,
• Manifold absolute pressure (MAP) sensor the PCM stops operating the injectors, ignition coil,
• Throttle position sensor (TPS) ASD relay and fuel pump relay.
• Camshaft position sensor signal (in the distributor)
• Park/Neutral switch (gear indicator signal—auto, THROTTLE BODY
trans, only) Filtered air from the air cleaner enters the intake
If the vehicle is under hard deceleration with the manifold through the throttle body (Fig. 22). Fuel
proper rpm and closed throttle conditions, the PCM does not enter the intake manifold through the throt
will ignore the oxygen sensor input signal. The PCM tle body. Fuel is sprayed into the manifold by the
will enter a fuel cut-off strategy in which it will not fuel injectors. The throttle body is mounted on the
supply battery voltage to the injectors. If a hard de intake manifold. It contains an air control passage
celeration does not exist, the PCM will determine the (Fig. 23) controlled by an Idle Air Control (IAC) mo
proper injector pulse width and continue injection. tor. The air control passage is used to supply air for
Based on the above inputs, the PCM will adjust en idle conditions. A throttle valve (plate) is used to
gine idle speed through the idle air control (IAC) mo supply air for above idle conditions.
tor. The throttle position sensor (TPS) and idle air con
The PCM adjusts ignition timing by turning the trol (IAC) motor are attached to the throttle body.
ground path to the coil on and off. The accelerator pedal cable, speed control cable and
The PCM opens the ground circuit to the A/C transmission control cable (when equipped) are con
clutch relay to disengage the A/C compressor clutch. nected to the throttle arm.
This is done until the vehicle is no longer under de A (factory adjusted) set screw is used to mechani
celeration (if the A/C system is operating). cally limit the position of the throttle body throttle
14 - 30 FUEL S Y S T E 1 4
IDLE A I R ' V NUMBERED
THROTTLE
CONTROL MOTOR TAG
ARM
TPS
J9314-16 F U E L RAIL J9314-15

inn—rr
Fig. 22 Throttle Body—Typical Fig. 24 Fuel Rail—Typical
IDLE A I R IDLE A I R
CONTROL CONTROL MOTOR SUPPLY
PASSAGE TUBE
INLET
THROTTLE
PLATE
IDLE A I R
CONTROL FUEL PRESSURE
PASSAGE J9314-14 REGULATOR J9114-38"
Fig. 23 Idle Air Control Passage Fig. 25 Fuel Pressure Regulator—Typical

plate. Never attempt to adjust the engine idle pressure will be 55-69 kPa (8-10 psi) higher if vac
speed using this screw. All idle speed functions are uum is not applied to the regulator.
controlled by the PCM. The pressure regulator contains a diaphragm, cali
brated spring and a fuel return valve (Fig. 26). Fuel
FUEL RAIL pressure operates on one side of the regulator, while
The fuel rail supplies fuel to the injectors and is spring pressure and intake manifold vacuum operate
mounted to the intake manifold (Fig. 24). The fuel on the other side. Spring pressure on one side of the
pressure regulator is attached to the rail and the fuel diaphragm tries to force the return valve closed. Fuel
pressure test port is integral with the rail. The fuel pressure on other side of diaphragm, with assistance
rail is not repairable. from manifold vacuum on spring side of diaphragm,
act against spring pressure to open the return valve.
FUEL PRESSURE REGULATOR System fuel pressure is the amount of fuel pressure
The fuel pressure regulator (Fig. 25) is a mechani
required to force against spring pressure and unseat
cal device that is not controlled by the powertrain
the return valve.
control module (PCM).
The fuel pressure regulator used is a vacuum bal Without vacuum applied to the spring side of the
anced, nonadjustable type. The regulator is mounted regulator, the spring is calibrated to open the fuel re
on the output end of the fuel rail and is connected to turn outlet. This happens when the pressure differen
intake manifold vacuum. The fuel return tube (to the tial between the fuel injectors and the intake
fuel tank) is connected to the fuel pressure regulator. manifold reaches approximately 269 kPa (39 psi).
The regulator is calibrated to maintain fuel system Since manifold vacuum varies with engine operating
pressure at approximately 214 kPa (31 psi). This is conditions, the amount of vacuum applied to the
with vacuum applied while the engine is at idle. Fuel spring side of the diaphragm varies. For this reason,
J FUEL SYSTEM 14 - 3 1
MANIFOLD
fuel pressure varies, depending upon intake manifold
vacuum. With low vacuum, such as during wide open
throttle conditions, minimal vacuum assistance is
available. Full spring pressure is exerted to seal the
fuel outlet. This causes the system pressure to in
crease. With high vacuum, such as at engine idle or
during vehicle deceleration, fuel pressure on one side
of the diaphragm is balanced by intake manifold
pressure. This is done on the spring side of the dia
phragm and results in lower system fuel pressure.
FUEL INLET
VALVE VALVE
CLOSED OPEN
J9214-11
Fig. 26 Fuel Pressure Regulator Operation—Typical

MPI SYSTEM—GENERAL DIAGNOSIS
INDEX
page page
Camshaft Position Sensor Test . 47 Manifold Absolute Pressure (MAP) Sensor Test . 47
Coolant Temperature Sensor Test 47 On-Board Diagnostics (OBD) . . . . . . . . . . . . . . . . 51
Crankshaft Position Sensor Test 48 Oxygen Sensor (0 ) Heating Element Test
2 49
Diagnostic Trouble Code (DTC) 54 Powertrain Control Module (PCM) 60-Way
D R B II Scan Tool . 54 Connector 38
Fuel System Pressure Test 51 Relays—Operation/Testing 50
General Information 32 Starter Motor Relay Test . . . . . . . . . . . . . . . . . . . 51
Idle Air Control Motor Test 49 System Schematics 38
Injector Test . 51 Throttle Position Sensor ( T P S ) Test . . . . . . . . . . 48
Intake Air Temperature Sensor Test 47 Visual Inspection 32
GENERAL INFORMATION PCM

All 2.5L 4 cylinder and 4.0L 6 cylinder engines are
equipped with sequential Multi-Port Fuel Injection
(MPI). The MPI system provides precise air/fuel ra
tios for all driving conditions.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor
rectly routed wires and hoses should be made. This
should be done before attempting to diagnose or ser
vice the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will in
clude the following checks:
(1) Verify that the 60-way connector is fully in
serted into the connector of the Powertrain Control
Module (PCM) (Figs. 1 or 2). Verify that the connec Fig. 2 PCM-XJ Models
tor mounting screw is tightened to 4 N*m (35 in. lbs.) diator fan relay (if equipped) connections. Inspect
torque. starter motor relay connections. Inspect relays for
signs of physical damage and corrosion. The relays
are installed in the Power Distribution Center (PDC)
(Figs. 3 or 4).
Fig. 1 PCM-YJ Models

(2) Inspect the battery cable connections. Be sure
they are clean and tight.
(3) Inspect fuel pump relay and air conditioning
compressor clutch relay (if equipped). Inspect ballast Fig. 3 PDC- YJ Models
resistor bypass relay (XJ models), ASD relay and ra-
firmly connected to the distributor cap and the spark

plugs in their correct firing order. Be sure that coil
cable is firmly connected to distributor cap and coil.
Be sure that camshaft position sensor wire connector
is firmly connected to harness connector (Figs. 7 or
8). Inspect spark plug condition. Refer to Group 8D,
Ignition System. Connect vehicle to an oscilloscope
and inspect spark events for fouled or damaged spark
plugs or cables.
J9114-91
Fig. 4 PDC-KJ Models

(4) Inspect ignition coil connections. Verify that
coil secondary cable is firmly connected to coil (Figs.
5 or 6).
Fig. 7 Distributor and Wiring—2.5L Engine

COIL
Fig. 5 ignition Coil—2.5L Engine
SENSOR CONNECTOR J9314-133
Fig. 8 Distributor and Wiring—4.0L Engine

(6) Verify that generator output wire, generator
connector and ground wire are firmly connected to
the generator (Fig. 9).
(7) Inspect the system ground connections at the
cylinder block behind the engine oil dipstick tube
(Fig. 10).
(8) Verify that crankcase ventilation (CCV) fresh
air hose is firmly connected to cylinder head and air
cleaner covers (Figs. 11 or 12).
(9) On XJ models, inspect the ballast resistor by
Fig. 6 Ignition Coil—4.0L Engine
pass relay connections (Fig. 13).
(5) Verify that distributor cap is correctly attached
to distributor. Be sure that spark plug cables are
Fig. 9 Generator Connector and Output Wire Fig. 12 CCV System—4.0L Engine
Connections—Typical
Fig. 13 Ballast Bypass Relay—XJ Models

Fig. 10 System Ground Connections—Typical
Fig. 14 Pressure Regulator Vacuum Hose—2.5L

Fig. 11 CCV System—2.51 Engine Engine
(10) Verify that vacuum hose is firmly connected (11) Inspect fuel tube quick-connect fitting-to-fuel
to fuel pressure regulator and manifold fitting (Figs. rail connections (Fig. 16),
14 or 15).
FUEL SYSTEM 14 - 35
J
Fig. 16 Fuel Supply Tube—Typical
Fig. 15 Pressure Regulator Vacuum Hose—4.0L

Engine
(12) Verify that hose connections to all ports of
vacuum fittings on intake manifold are tight and not
leaking.
(13) Inspect accelerator cable, transmission throt
tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or re
strictions (Fig. 17).
(14) If equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster (Fig. 18).
(15) On XJ models equipped with 4.0L engine and
A/C, verify that auxiliary cooling fan wire connector
is firmly connected to harness (Fig. 19).
(16) Inspect the air cleaner inlet and air filter ele
ment for restrictions.
(17) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
Fig. 19 Auxiliary Cooling Fan Connector—XJ with
4.0L Engine
(18) Verify that intake manifold air temperature

sensor wire connector is firmly connected to harness
connector (Figs. 20 or 21).
(J9014-29
Fig. 22 Engine Ground Strap Connections—Typical

J938D-13,
ISJ VACUUM
CONNECTION
J9114-10
THROTTLE
POSITION
SENSOR Fig. 23 MAP Sensor—Typical
J9314-140 V NUMBERED
TAG
(19) Inspect engine ground strap connections at
dash panel and rear cylinder head bolt (Fig. 22).
(20) Verify that MAP sensor electrical connector is
firmly connected to MAP sensor (Fig. 23). Verify that
vacuum hose is firmly connected to MAP sensor and
to the intake manifold.
(21) Verify that fuel injector wire harness connec
tors are firmly connected to the fuel injectors in the
correct order. Each harness connector is tagged with
the number of its corresponding fuel injector (Fig.
24).
F U E L RAIL J9314-15
(22) Verify that harness connectors are firmly con <t]—n i
nected to idle air control (IAC) motor and throttle po
sition sensor (TPS) (Figs. 2 0 , 21 or 25). Fig. 24 Fuel Injector Wire Harness—Typical
(23) Verify that wire harness connector is firmly
connected to the coolant temperature sensor (Fig.
26).
FUEL SYSTEM 14 - 37
J (26) Inspect for pinched or leaking fuel tubes. In
spect for pinched cracked or leaking fuel hoses.
(27) Inspect for exhaust system restrictions such as
pinched exhaust pipes, collapsed muffler or plugged
catalytic convertor.
(28) If equipped with automatic transmission, ver
ify that electrical harness is firmly connected to
park/neutral safety switch. Refer to Automatic
Transmission section of Group 21.
(29) Verify that the harness connector is firmly
connected to the vehicle speed sensor (Fig. 28).
Fig. 25 IAC Motor and TPS—2.5L Engine
Fig. 28 Vehicle Speed Sensor—Typical

(30) Verify that fuel pump module wire connector
is firmly connected to harness connector.

(24) Verify that oxygen sensor wire connector is
firmly connected to the sensor. Inspect sensor and
connector for damage (Fig. 27).
Fig. 27 Oxygen Sensor Location—Typical

FUEL P U M P / '
GAUGE S E N D E R
W I R E CONNECTOR
Fig. 29 Fuel Pump Module Connector and Fuel Hoses—Typical

(31) Inspect fuel hoses at fuel pump module for
SOLENOID cracks or leaks (Fig. 29).
TERMINAL
NUT BATTERY (32) Inspect transmission torque convertor housing
POSITIVE (automatic transmission) or clutch housing (manual
CABLE
transmission) for damage to timing ring on drive
plate/flywheel.
(33) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components (Fig. 30).
POWERTRAIN CONTROL MODULE (PCM) 60-WAY

CONNECTOR
SOLENOID
BRUSH FEED Terminal identification and specific circuit applica
WIRE WIRE tions for the 2.5L 4 cylinder and 4.0L 6 cylinder en
J9014-62
gines are detailed in the PCM connector charts (Figs.
31, 32, 33 or 34).
Fig. 30 Starter Solenoid Connections—Typical
SYSTEM SCHEMATICS
Fuel system schematics for the 2.5L 4 cylinder and
4.0L 6 cylinder engines are shown in figures 35, 36,
37 and 38.
WIRE WIRE
CAV DESCRIPTION CAV DESCRIPTION
(
COLOR COLOR
' 1 20 D G / R D 37
2 18TN/BK ENGINE COOLANT TEMP. SENSOR 38
3 14PK/YL 39 18GY/RD IDLE A I R C O N T R O L M O T O R
4 18BK/LB SENSOR GROUND (PCM) 40 18 B R / W T IDLE A I R C O N T R O L M O T O R
5 16BK/WT 41 18BK/DB
6 20 V T / W T 42
7 18 O R 8-VOLT O U T P U T 43 20 G Y / L B
8 44 18TN/YL CAMSHAFT POSITION S E N S O R SIGNAL
9 18DB/WT 45 2 0 LG DATA LINK C O N N E C T O R
10 18DB/OR P O W E R STEERING PRESSURE S E N S O R 46
11 16 BK 47 20 W T / O R VEHICLE S P E E D S E N S O R S I G N A L
12 16 BK 48
13 18LB/BR 49
14 18YL/WT 50
15 18 T N 51 18DB/YL
16 18 W T / D B 52
17 53
18 54 20 O R / B K
19 18GY 55
20 18 D G G E N E R A T O R FIELD C O N T R O L 56 20 GY/PK S E R V I C E R E M I N D E R I N D I C A T O R (SRI) L A M P
21 18BK/RD I N T A K E AIR T E M P . S E N S O R 57 18VT/BK GENERATOR FEED/INJECTOR SENSE
22 18 0 R / D B 58
23 59 18 V T / B K IDLE A I R C O N T R O L M O T O R
24 18GY/BK C R A N K S H A F POSITION S E N S O R 60 18YL/BK IDLE AIR C O N T R O L M O T O R
25 2 0 PK D A T A LINK C O N N E C T O R W I R E COLOR CODES LB LIGHT BLUE VT VIOIET
26 BK BLACK LG LIGHT G R E E N WT WHITE
27 18 LB BR BROWN OR ORANGE YL YELLOW
28 18 BR DB DARK BLUE PK PINK

DG DARK GREEN RD RED
29 18 W T / P K T O R Q U E C O N V E R T O R C L U T C H F E E D (BRAKE)
GY GRAY TN TAN
30
JDJUL
31
32 20 BK/PK M A L F U N C T I O N INDICATOR LAMP X XX
33 OOOOOOOOOO OOOOOOOOOO
3 4 5 6 7 B 9 II 12 13 14 15 16 17 18 19 20
34 18DB/OR OOOOOOOOOO ! OOOOOOOOOO
CONNECTOR K 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
35 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
TERMINAL SIDE OOOOOOOOOO OOOOOOOOOO
36 XT
SHOWN TJUir - u i n rL X Z Z J9314 156
Fig. 31 PCM — YJ with 2.5L Engine

CAV WIRE WIRE
COLOR DESCRIPTION CAV COLOR DESCRIPTION
1 20 D G / R D 37
2 18TN/BK ENGINE COOLANT TEMP. SENSOR 38 18 B K / P K
3 16RD/WT 39 18GY/RD IDLE A I R C O N T R O L M O T O R m
4 18BK/LB SENSOR GROUND (PCM) 40 18 B R / W T IDLE AIR C O N T R O L M O T O R
r-
5
oo
18BK/WT 41 18BK/DG -<
6 20 V T / W T 42 00
—I
7 18 O R 8-VOLT O U T P U T 43 20 GY/LB
m
8 44 18TN/YL CAMSHAFT POSITION SENSOR
9 18DB/WT 45 2 0 LG D A T A LINK C O N N E C T O R
10 46
11 16 BK 47 20WT/OR VEHICLE S P E E D S E N S O R
12 16 BK 48
13 18LB/BR 49
14 18YL/WT 50
15 18 T N 51 18DB/YL
16 18WT/DB 52
17 53
18 54 20 O R / B K
19 18 G Y 55
20 18 DG G E N E R A T O R FIELD C O N T R O L 56 20 GY/PK S E R V I C E R E M I N D E R I N D I C A T O R (SRI) L A M P
21 18BK/RD INTAKE AIR T E M P . S E N S O R 57 18DG/OR GENERATOR FEED/INJECTOR SENSE
22 18 0 R / D B 58 18LG/BK
23 59 18VT/BK IDLE A I R C O N T R O L M O T O R
24 18GY/BK CRANKSHAFT POSITION SENSOR 60 18YL/BK IDLE A I R C O N T R O L M O T O R
25 20 BK DATA UNK CONNECTOR W I R E COLOR CODES LB LIGHT BLUE VT VIOLET
26 BK BLACK LG LIGHT G R E E N WT WHITE

BR BROWN OR ORANGE YL YELLOW
27 1 8 LB
DB DARK BLUE PK PINK
28 18 BR
29 18WT/PK T O R Q U E C O N V E R T O R C L U T C H F E E D (BRAKE)
GY GRAY TN TAN
30 18BR/YL
J2fL£L
31 •DAT!
32 20 B K / P K M A L F U N C T I O N INDICATOR LAMP TT- X
OOOOOOOOOO OOOOOOOOOO
33 9 10 11 12 13 14 15 16 17 18 19 20
OOOOOOOOOO ! OOOOOOOOOO
34 18DB/OR 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
CONNECTOR 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
35 TERMINAL SIDE OOOOOOOOOO
X OOOOOOOOOO
36 SHOWN -imr inar J9314-157
Fig. 32 PCM Connector—YJ with 4.0L Engine

WIRE WIRE DESCRIPTION
CAV COLOR DESCRIPTION CAV COLOR
20 D G / R D 37 20 R D / D B BALLAST BYPASS RESISTOR RELAY
20 T N / B K ENGINE COOLANT TEMP. SENSOR 38
14 RD DIRECT B A T T E R Y V O L T A G E (ASD RELAY) 39 18GY/RD IDLE AIR C O N T R O L M O T O R
18BK/LB S E N S O R G R O U N D (PCM) 40 18 B R / W T IDLE A I R C O N T R O L M O T O R
16BK/WT 41 18 BK/DG
20 V T / W T 42
18 O R 43 20GY/LB
44 18TN/YL CAMSHAFT POSITION SENSOR
14 DB 45 2 0 LG D A T A LINK C O N N E C T O R
10 18DB/WT P O W E R STEERING PRESSURE SENSOR 46
11 16BK/TN 47 20WT/OR VEHICLE S P E E D S E N S O R
12 16BK/TN 48 20 B R / R D
13 18LB/BR 49 20YL/RD
14 18YL/WT 50 20WT/LG
15 18TN 51 20 DB/YL
16 18WT/DB 52
17 53 20 LG/RD
18 54 20 O R / B K
19 18 G Y 55
20 18DG G E N E R A T O R FIELD C O N T R O L 56 20 GY/PK SERVICE R E M I N D E R I N D I C A T O R (SRI) L A M P
21 18BK/RD INTAKE AIR T E M P . S E N S O R 57 18DG/OR GENERATOR FEED/INJECTOR SENSE
22 18 0 R / D B 58 18LG/BK
24 18GY/BK CRANKSHAFT POSITION S E N S O R 60 18YL/BK IDLE A I R C O N T R O L M O T O R
25 2 0 PK D A T A LINK C O N N E C T O R WIRE COLOR CODES LB LIGHT BLUE VT VIOLET
26 BK BLACK LG UGHT GREEN W T WHITE
27 BR BROWN OR ORANGE YL YELLOW
16 LB
28 16 BR DB DARK BLUE PK PINK
29 18WT/PK T O R Q U E C O N V E R T O R C L U T C H F E E D (BRAKE)
GY GRAY TN TAN
30
J2SUL
31
32 20 B K / P K M A L F U N C T I O N INDICATOR LAMP XX XX •<
33
34
35
36
20TN/RD
20 DB/OR
20 DG/YL CHECK G A U G E LAMP

CONNECTOR
TERMINAL SIDE
SHOWN
OOOOOOOOOO
2
OOOOOOOOOO
3 4 5 6 7 8 9
21 22 23 24 25 26 27 28 29 30
1
41 42 43 44 45 46 47 48 49 50
OOOOOOOOOO
IT.
"uiar
itOOOOOOOOOO
11 12 13 14 15 16 17 18 19 20
OOOOOOOOOO
31 32 33 34 35 36 37 38 39 40
51 52 53 54 55 56 57 58 59 60
OOOOOOOOOO
-uinr
J9314-158
m
Fig. 33 PCM Connector—XJ with 2.5L Engine

WIRE WIRE
CAV DESCRIPTION CAV DESCRIPTION
COLOR COLOR
1 20 DG/RD 37 20 R D / D B BALLAST BYPASS RESISTOR RELAY
2 20TN/BK ENGINE COOLANT TEMP. SENSOR 38 18PK/BK
3 14 R D 39 18GY/RD IDLE A I R C O N T R O L M O T O R
4 18BK/LB S E N S O R G R O U N D (PCM) 40 18 B R / W T IDLE A I R C O N T R O L M O T O R
5 16BK/WT 41 18BK/DG
6 20 V T / W T 42
7 18 O R 43 20 GY/LB
8 44 18TN/YL CAMSHAFT POSITION SENSOR
9 14 D B 45 2 0 LG D A T A LINK C O N N E C T O R
10 46 18WT/BK
11 16BK/TN 47 20 W T / O R VEHICLE S P E E D S E N S O R S I G N A L
12 16BK/TN 48 20 BR/RD
13 18LB/BR 49 20 YL/RD
14 18YL/WT 50 20WT/LG
15 18 T N 51 20 DB/YL
16 18WT/DB 52
17 53 20 LG/RD
18 54 20 O R / B K
19 18 G Y 55
20 18DG G E N E R A T O R FIELD C O N T R O L 56 20 GY/PK S E R V I C E R E M I N D E R I N D I C A T O R (SRI) L A M P
21 18BK/RD INTAKE AIR TEMP. S E N S O R 57 18DG/OR GENERATOR FEED/INJECTOR SENSE
22 18 0 R / D B 58 18LG/BK
24 18GY/BK CRANKSHAFT POSITION S E N S O R 60 18YL/BK IDLE A I R C O N T R O L M O T O R
25 2 0 PK D A T A LINK C O N N E C T O R W I R E COLOR CODES LB LIGHT BLUE VT VIOLET
26 18VT/BR BK BLACK LG LIGHT G R E E N WT WHITE
27 16 LB BR BROWN OR ORANGE YL YELLOW

DB DARK BLUE PK PINK
28 16 LG
29 18WT/PK T O R Q U E C O N V E R T O R C L U T C H F E E D (BRAKE S I G N A L )
GY GRAY TN TAN
30 18BR/YL
jmiL
31 20 DB/PK
32 20 BK/PK M A L F U N C T I O N INDICATOR LAMP T
33 20TN/RD 3 4 5 6 7 11 12 13 14 15 16 17 18 19 20
34 20 DB/OR , 21 22 23 24 25 26 27 28 29 30 3! 32 33 34 35 36 37 38 39 40
CONNECTOR 41 42 43 44. 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
35 TERMINAL SIDE OOOOOOOOOO OOOOOOOOOO
36 20 DG/YL CHECK G A U G E LAMP SHOWN n ="mar
r -uinr
J9314-159
Fig. 34 PCM —XJ with 4,0L Engine

AFTERMARKET
A/C
INTERCONNECT <3>
COOLANT TEMP
AIR TEMP SENS
VEH SPD SENS
TPS SIGNAL
5 VOLTS
MAP SENSOR IAC 1
SENSOR P/U IAC 2
8 VOLTS SUPPLY IAC 3
CRANK POS P/U IAC A
P/S PRESS SW
SENSOR GROUND INJECT #2
02 SENSOR INJECT #4
INJECT #3
CAMSHAFT INJECT #1
POSITION ROWER
SENSOR STEERING BRAKE SWITCH IGNITION COIL
SWITCH SCIREC
SCI TRANS
I Tlj FUEL INJECTORS

lg 2
• START 4
'RUN
OFF
OFF J2
STOP
LAMPS
BAT I I
START
RELAY
FUEL PUMP
RELAY
AUTO
SHUT-DOWN
RELAY
- > FUEL
PUMP
ENGINE GROUND
J9314-150
Fig. 35 System Schematic—YJ Models with 2.5L Engine

J9314-151
Fig. 36 System Schematic—YJ Models with 4.0L Engine

FUEL SYSTEM
"Cuuuu3" '
C A/C
CLUTCH
<3), <3>
THROTTLE
POSITION
ENGINE COOLANT /
!
^t^7r-
>\TEMP
0 GO
•<
SENSOR
INTAKE AIR/Ov TEMP
VEHICLE
SPEED JL ?t^75
TO OTHER
SENSOR COOLANT TEMP
MODULES
AIR TEMP SENS
CCD +
TRANSMISSION VEH SPD SENS
CCD -
MODULE TPS SIGNAL
5 VOLTS 59 a
AAAP SENSOR IDLE AIR
40 B CONTROL MOTOR
SENSOR P/U 60 C
8 VOLTS SUPPLY 39 d
CRANK POS P/U
1
CRANK POSITION
SENSOR
SENSOR GROUND
02 SENSOR
BRAKE SWITCH
SPEED CONTROL SPEED CONTROL
COAST/SET
ON/OFF
RESUME/ACCEL
FUEL INJECTORS
* IGNITION SW .
<p START
BRAKE
OFF SWITCH
STOP
1
LAMPS
fSTART
'relay
FUEL PUMP
RELAY
AUTO
SHUT-DOWN
RELAY COOLING FAN
J AUTO RELAY
• MANUAL J ONLY
I ONLY
eutralX
CH >
1
L4 BODY "
GROUND
" ENGINE "
GROUND
BALLAST
RESISTOR
J9314-153
Fig. 38 System Schematic—XJ Models with 4.0L Engine

CAMSHAFT POSITION SENSOR TEST SENSOR RESISTANCE (OHMS)-COOLANT

Refer to Group 8D, Ignition Systems, for Camshaft TEMPERATURE SENSOR/MANIFOLD AIR TEM
Position Sensor testing. PERATURE
COOLANT TEMPERATURE SENSOR TEST

Disconnect wire harness connector from engine TEMPERATURE RESISTANCE (OHMS)
coolant temperature sensor (Fig. 39).
C F MIN MAX
^THERMOSTAT
HOUSING -40 -40 291,490 381,710
-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
J9114-9 110 230 480 540
120 248 370 410
J928D-4
Test the resistance of the sensor with a high input
impedance (digital) volt-ohmmeter. The resistance
should be less than 1000 ohms with the engine at its
correct operating temperature. Refer to the Coolant
Temperature Sensor/Manifold Air Temperature Sen
sor resistance chart. Replace the sensor if it is not
within the range of resistance specified in the chart.
Test continuity of the wire harness. Do this be
tween the Powertrain Control Module (PCM) wire
harness connector terminal-2 and the sensor connec
tor terminal. Also test continuity of wire harness ter
minal-4 to the sensor connector terminal. Repair the
wire harness if an open circuit is indicated. THROTTLE
POSITION
INTAKE AIR TEMPERATURE SENSOR TEST SENSOR
Disconnect the wire harness connector from the in J9314-140
take manifold air temperature sensor (Figs. 40 or
41). Fig. 40 Air Temperature Sensor—2.5L Engine
Test the resistance of the sensor with an input im
pedance (digital) volt-ohmmeter. The resistance MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
should be less than 4000 ohms with the engine at op TEST
erating temperature. The longer the engine idles, the Inspect the MAP sensor vacuum hose connections
warmer the intake manifold temperature will be at the throttle body and sensor. Repair as necessary.
come. Refer to the Coolant Temperature Sensor/Man
CAUTION: When testing, do not remove the electri
ifold Air Temperature Sensor resistance chart.
cal connector from MAP sensor (Fig. 42). Be sure
Replace the sensor if it is not within the range of re
sistance specified in the chart. that the MAP sensor harness wires are not dam
Test the resistance of the wire harness. Do this be aged by the test meter probes.
tween the Powertrain Control Module (PCM) wire
Test the MAP sensor output voltage at the MAP
harness connector terminal-2 and the sensor connec
tor terminal. Also test terminal-4 to the sensor con sensor connector between terminals A and B (as
nector terminal. Repair the wire harness as marked on the sensor body) (Fig. 43). With the igni
necessary if the resistance is greater than 1 ohm. tion switch ON and the engine OFF, output voltage
A. Ground
Fig. 41 Air Temperature Sensor—4.0L Engine B . Output Voltage
C. 5 Volts
J8914-91
Fig. 43 MAP Sensor Connector Terminals—Typical

PCM. If terminal-4 has a short circuit to 12 volts,
correct this condition before replacing the PCM.
CRANKSHAFT POSITION SENSOR TEST

Refer to Group 8D, Ignition Systems for test proce
dures.
THROTTLE POSITION SENSOR (TPS) TEST

The throttle position sensor (TPS) can be tested
with a digital voltmeter. The center terminal of the
TPS is the output terminal (Figs. 44 or 45).

should be 4-to-5 volts. The voltage should drop to 1.5-
to-2.1 volts with a neutral-hot idle speed condition.
Test Powertrain Control Module (PCM) (termi-
nal-5) for the same voltage described above to verify
the wire harness condition. Repair as necessary.
Test MAP sensor supply voltage at sensor connec
tor between terminals A and C (Fig. 43) with the ig
nition ON and engine OFF. The voltage should be
approximately 5 volts (±0.5V). Five volts (±0.5V)
should also be at terminal-6 of the PCM wire harness
connector. Repair or replace the wire harness as nec
essary.
Test the MAP sensor ground circuit at sensor con
nector terminal-A (Fig. 43) and PCM connector ter
minal-4. Repair the wire harness if necessary. Fig. 44 TPS Testing—2.5L Engine
Test the MAP sensor ground circuit at the PCM With the ignition key in the ON position, back-
connector between terminal-4 and terminal-11 with probe the TPS connector. Check the TPS output volt
an ohmmeter. If the ohmmeter indicates an open cir age at the center terminal wire of the connector.
cuit, inspect for a defective sensor ground connection. Check this at idle (throttle plate closed) and at wide
Refer to Group 8W, Wiring for location of engine open throttle (WOT). At idle, TPS output voltage
grounds. If the ground connection is good, replace the should must be greater than 200 millivolts. At wide
open throttle, TPS output voltage must be less than
Fig. 45 TPS Testing—4.0L Engine Fig. 47 IAC Motor Testing— Typical

4.8 volts. The output voltage should increase gradu • Provide proper ventilation while operating the en
ally as the throttle plate is slowly opened from idle gine
to WOT. • Always return the engine idle speed to normal be
fore disconnecting the exerciser tool
OXYGEN SENSOR ( 0 ) HEATING ELEMENT TEST
2 (1) With the ignition OFF, disconnect the IAC mo
The oxygen sensor heating element can be tested tor wire connector at throttle body (Fig. 47).
with an ohmmeter as follows: (2) Plug the exerciser tool number 7558 harness
With the sensor at room temperature 25 degrees C connector into the IAC motor.
(77 degrees F), disconnect the 0 sensor connector (Fig.
2
(3) Connect the red clip of exerciser tool 7558 to
46). Connect the ohmmeter test leads across the white battery positive terminal. Connect the black clip to
wire terminals of the sensor connector. Resistance
negative battery terminal. The red light on the exer
should be between 5 and 7 ohms. Replace the sensor if
ciser tool will flash when the tool is properly con
the ohmmeter displays an infinity (open) reading.
nected.
(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.
(5) Move the switch to the HIGH position. The en
gine speed should increase. Move the switch to the
LOW position. The engine speed should decrease.
(a) If the engine speed changes while using the
exerciser tool, the IAC motor is functioning prop
erly. Disconnect the exerciser tool and connect the
IAC motor wire connector to the stepper motor.
(b) If the engine speed does not change, turn the
ignition OFF and proceed to step (6). Do not discon
nect exerciser tool from the IAC motor.
Fig. 46 Oxygen Sensor— Typical (6) Remove the IAC motor from the throttle body. Do
not remove IAC motor housing from throttle body.
IDLE AIR CONTROL MOTOR T E S T
Idle Air Control (IAC) Motor operation can be tested CAUTION: When checking IAC motor operation with
using special exerciser tool number 7558 (Fig. 47). the motor removed from the throttle body, do not
CAUTION: Proper safety precautions must be taken extend the pintle (Fig. 48) more than 6.35 mm (.250
when testing the idle air control motor: in). If the pintle is extended more than this amount,
it may separate from the IAC motor. The IAC motor
• Set the parking brake and block the drive wheels must be replaced if the pintle separates from the
• Route all tester cables away from the cooling fans, motor.
drive belt, pulleys and exhaust components
IDLE A I R C O N T R O L WIRE HARNESS found, refer to the DRB II scan tool and the appro
STEPPER MOTOR CONNECTION priate Powertrain Diagnostics Procedures service
manual.
RELAYS ~ OPERATION/TESTING
n—f
OPERATION
The following operations/tests apply to these
relays only: automatic shut down (ASD) and fuel
pump. For operations/tests on all other relays, refer
to the appropriate section of this service manual.
The relay terminal numbers from (Fig. 49) can be
found on the bottom of the relay:
• Terminal number 30 is connected to battery volt
PINTLE age and can be switched or B + (hot) at all times.
J9314-19
• Terminal number 87A is connected (a circuit is
Fig. 48 Idle Air Control (IAC) Motor Pintle formed) to terminal 30 in the de-energized (normally
OFF) position.
(7) With the ignition OFF, cycle the exerciser tool • Terminal number 87 is connected (a circuit is
switch between the HIGH and LOW positions. Ob formed) to terminal 30 in the energized (ON) posi
serve the pintle. The pintle should move in-and-out tion. Terminal number 87 then supplies battery volt
of the motor. age to the component being operated.
(a) If the pintle does not move, replace the idle • Terminal number 86 is connected to a switched
air control motor. Start the engine and test the re ( + ) power source.
placement motor operation as described in step (5). • Terminal number 85 is grounded by the power-
(b) If the pintle operates properly, check the idle train control module (PCM).
air control motor bore in the throttle body bore for
blockage and clean as necessary. Reinstall the idle TESTING
air control motor and retest. If blockage is not (1) Remove relay before testing.
BOTTOM VIEW RELAY

OF RELAY CONNECTOR
DE-ENERGIZED ENERGIZED
RELAY RELAY
9214-157
Fig. 49 Relay Terminals

(2) Using an ohmmeter, perform a resistance test be Certain criteria must be met for a diagnostic trou
tween terminals 85 and 86. Resistance value (ohms) ble code (DTC) to be entered into PCM memory. The
should be 75 ±5 ohms for resistor equipped relays. criteria may be a specific range of engine rpm, en
(3) Connect the ohmmeter between terminals number gine temperature and/or input voltage to the PCM.
87A and 30. Continuity should be present at this time. It is possible that a DTC for a monitored circuit may
(4) Connect the ohmmeter between terminals number not be entered into memory even though a malfunction
87 and 30. Continuity should not be present at this has occurred. This may happen because one of the DTC
time. criteria for the circuit has not been met. Example: as
(5) Use a set of jumper wires (16 gauge or small sume that one of the criteria for the MAP sensor circuit
er). Connect one jumper wire between terminal num is that the engine must be operating between 750 and
ber 85 (on the relay) to the ground side (-) of a 12 2000 rpm to be monitored for a DTC. If the MAP sensor
Volt power source. output circuit shorts to ground when the engine rpm is
(6) Attach the other jumper wire to the positive above 2400 rpm, a 0 volt input will be seen by the
side ( + ) of a 12V power source. Do not connect the PCM. A DTC will not be entered into memory because
jumper wire to relay at this time. the condition does not occur within the specified rpm
range.
CAUTION: DO NOT ALLOW THE OHMMETER TO A DTC indicates that the powertrain control module
CONTACT TERMINALS 85 OR 86 DURING THESE (PCM) has recognized an abnormal signal in a circuit or
TESTS. DAMAGE TO OHMMETER MAY RESULT. the system. A DTC may indicate the result of a failure,
but never identify the failed component directly.
(7) Attach the other jumper wire (12V + ) to termi There are several operating conditions that the
nal number 86. This will activate the relay. Continu PCM does not monitor and set a DTC for. Refer to
ity should now be present between terminals number the following Monitored Circuits and Non-Monitored
87 and 30. Continuity should not be present between Circuits in this section.
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12 MONITORED CIRCUITS
Volt power source. The powertrain control module (PCM) can detect
If continuity or resistance tests did not pass, re certain problems in the fuel injection system.
place relay. If tests passed, refer to (Figs. 35, 36, 37 Open or Shorted Circuit - The PCM can deter
or 38) for (fuel system) relay wiring schematics. Also mine if sensor output (which is the input to PCM) is
refer to Group 8W, Wiring Diagrams for additional within proper range. It also determines if the circuit
circuit information. is open or shorted.
Output Device Current Flow - The PCM senses
STARTER MOTOR RELAY TEST
whether the output devices are hooked up.
Refer to Group 8A, Battery/Starting/Charging/Sys
If there is a problem with the circuit, the PCM
tem Diagnostics, for starter motor relay testing.
senses whether the circuit is open, shorted to ground
INJECTOR TEST (-), or shorted to ( + ) voltage.
Disconnect the injector wire connector from the in Oxygen Sensor - The PCM can determine if the ox
jector. Place an ohmmeter on the injector terminals. ygen sensor is switching between rich and lean. This is,
Resistance reading should be approximately 14.5 once the system has entered Closed Loop. Refer to Open
ohms ±1.2 ohms at 20°C (68°F). Proceed to following Loop/Closed Loop Modes Of Operation in the Compo
Injector Diagnosis chart. nent Description/System Operation section for an expla
nation of Closed (or Open) Loop operation.
FUEL SYSTEM PRESSURE TEST
Refer to the Fuel Delivery System section of this NON-MONITORED CIRCUITS
group. See Fuel System Pressure Test. The PCM does not monitor the following circuits,
systems or conditions that could have malfunctions
ON-BOARD DIAGNOSTICS (OBD) that result in driveability problems. A Diagnostic
The Powertrain Control Module (PCM) has been Trouble Code (DTC) may not be displayed for these
programmed to monitor many different circuits of the conditions.
fuel injection system. If a problem is sensed in a Fuel Pressure: Fuel pressure is controlled by the
monitored circuit often enough to indicate an actual vacuum assisted fuel pressure regulator. The PCM
problem, a Diagnostic Trouble Code (DTC) is stored. cannot detect a clogged, fuel pump inlet filter, clogged
The DTC will be stored in the PCM memory for in-line fuel filter, or a pinched fuel supply or return
eventual display to the service technician. If the line. However, these could result in a rich or lean
problem is repaired or ceases to exist, the PCM can condition causing an oxygen sensor DTC to be stored
cels the DTC after 51 engine starts. in the PCM.
14 - 52 FUEL SYSTEM
INJECTOR DIAGNOSIS-VEHICLE RUNS ROUGH AND/OR HAS A MISS
DO PRELIMINARY INSPECTION OF START VEHICLE, PULL THE TEST THE INJECTOR RESISTANCE
DISTRIBUTOR CAP, IGNITION ELECTRICAL CONNECTORS OFF USING AN OHMMETER ACROSS
THE INJECTORS ONE AT A TIME THE INJECTOR TERMINALS WITH
CABLES SPARK PLUGS, AND
TO DETERMINE WHICH CYLINDER THE INJECTOR CONNECTOR
CHECK FOR VACUUM LEAKS.
IS NOT FIRING. REMOVED.
REPLACE THE INJECTOR .NO -
PLACE A 12 VOLT TEST LAMP

ACROSS THE INJECTOR
ELECTRICAL CONNECTOR
TERMINALS. OBSERVE THE TEST
LAMP WHILE CRANKING THE
ENGINE.
CHECK POWER FEED AND

GROUND CIRCUITS BETWEEN
AND THE INJECTOR CONNECTOR.
REFER TO WIRING SCHEMATIC -NO-
FOR COLOR CODES AND PIN
TERMINAL NUMBERS.
CIRCUIT IS OK. CHECK FOR FUEL

DELIVERY AT SUSPECT INJECTOR
YES BY REMOVING THE INJECTOR
TEST THE VEHICLE WITH THE DRB II FROM THE RAIL AND OBSERVING
SCAN TOOL FOR FUEL AND/OR RESTRICTIONS
IN THE RAIL OR INJECTOR FUEL
INLET.
NO YES
REPAIR OR REPLACE THE WIRING

HARNESS AS NECESSARY.
REPLACE INJECTOR IF VISUALLY

PLUGGED AT INJECTOR FUEL
INLET.
-NO
REPLACE FUEL RAIL IF VISUALLY
PLUGGED OR RESTRICTED AT
INJECTOR DELIVERY COUPLING.
WITH INJECTOR REMOVED FROM

THE FUEL RAIL, CONNECT A 12V
SOURCE TO ONE TERMINAL ON
THE INJECTOR CONNECTOR AND
A GROUND WIRE TO THE OTHER
TERMINAL. THE INJECTOR
SHOULD "CLICK" EACH TIME THE
GROUND WIRE IS CONNECTED
AND DISCONNECTED TO THE
TERMINAL.
REPLACE INJECTOR •NO-
INJECTOR IS OK
J9314-114
Secondary Ignition Circuit: The PCM cannot de ACCESSING DIAGNOSTIC TROUBLE CODES
tect an inoperative ignition coil, fouled or worn spark A stored Diagnostic Trouble Code (DTC) can be dis
plugs, ignition cross firing, or open circuited spark played by cycling the ignition key On-Off-On-Off-On
plug cables. within three seconds and observing the Malfunction
Engine Timing: The PCM cannot detect an incor Indicator Lamp. This lamp was formerly referred to
rectly indexed timing chain, camshaft sprocket or as the Check Engine Lamp. The lamp is located on
crankshaft sprocket. The PCM also cannot detect an the instrument panel.
incorrectly indexed distributor. However, these could They can also be displayed through the use of the
result in a rich or lean condition causing an oxygen Diagnostic Readout Box II (DRB II scan tool). The
sensor DTC to be stored in the PCM. DRB II connects to the data link connector in the en
Cylinder Compression: The PCM cannot detect gine compartment (Figs. 50 or 51). For operation of
uneven, low, or high engine cylinder compression. the DRB II, refer to the appropriate Powertrain Di
Exhaust System: The PCM cannot detect a agnostic Procedures service manual.
plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions: The PCM cannot de
termine if the fuel injector is clogged, or the wrong
injector is installed. However, these could result in a
rich or lean condition causing an oxygen sensor DTC
to be stored in the PCM.
Excessive Oil Consumption: Although the PCM
monitors exhaust stream oxygen content through ox
ygen sensor (closed loop), it cannot determine exces
sive oil consumption.
Throttle Body Air Flow: The PCM cannot detect
a clogged or restricted air cleaner inlet or air filter
element.
Evaporative System: The PCM will not detect a
restricted, plugged or loaded EVAP canister.
Vacuum Assist: Leaks or restrictions in the vac
uum circuits of vacuum assisted engine control sys Fig. 50 Data Link Connector—YJ Models—Typical
tem devices are not monitored by the PCM. However,
a vacuum leak at the MAP sensor will be monitored
and a diagnostic trouble code (DTC) will be gener
ated by the PCM.
Powertrain Control Module (PCM) System
Ground: The PCM cannot determine a poor system
ground. However, a DTC may be generated as a re
sult of this condition.
Powertrain Control Module (PCM) Connector
Engagement: The PCM cannot determine spread or
damaged connector pins. However, a DTC may be
generated as a result of this condition.
HIGH AND LOW LIMITS

The powertrain control module (PCM) compares in
put signal voltages from each input device. It will es
Fig. 51 Data Link Connector—XJ Models—Typical
tablish high and low limits that are programmed
into it for that device. If the input voltage is not EXAMPLES
within specifications and other Diagnostic Trouble • If the lamp flashes 4 times, pauses and flashes 1
Code (DTC) criteria are met, a DTC will be stored in more time, a Diagnostic Trouble Code (DTC) number
memory. Other DTC criteria might include engine 41 is indicated.
rpm limits or input voltages from other sensors or • If the lamp flashes 4 times, pauses and flashes 6
switches. The other inputs might have to be sensed more times, a Diagnostic Trouble Code (DTC) num
by the PCM when it senses a high or low input volt ber 46 is indicated.
age from the control system device in question. Refer to the Diagnostic Trouble Code (DTC) charts
for DTC identification.
If the problem is repaired or ceases to exist, the
Powertrain Control Module (PCM) cancels the DTC
after 51 engine starts.
<=S=> eg* D-l GROUND
Diagnostic Trouble Codes indicate the results of a D-2 N/C
failure, but never identify the failed component di
rectly. D-3 SCI TRANS
The circuits of the data link connector are shown
in (Fig. 52).
D-4 SCI RECEIVE
D-5 IGNITION
ERASING TROUBLE CODES
The DRB II scan tool must be used to erase a Di
J9214-20 D-6 NOT USED
agnostic Trouble Code (DTC). Refer to the appropri
Fig. 52 Data Link Connector Schematic
ate Powertrain Diagnostic Procedures service manual
for operation of the DRB II scan tool. DIAGNOSTIC TROUBLE CODE (DTC)
On the following pages, a list of diagnostic trouble
DRB II SCAN TOOL codes is provided for the 2.5L 4 cylinder and 4.0L 6
For operation of the DRB II scan tool, refer to the cylinder engines. A DTC indicates that the power-
train control module (PCM) has recognized an abnor
appropriate Powertrain Diagnostic Procedures ser
mal signal in a circuit or the system. A DTC may
vice manual. indicate the result of a failure, but never identify the
failed component directly.
DIAGNOSTIC TROUBLE CODE DESCRIPTION
DIAGNOSTIC TROUBLE CODE DRBII DISPLAY DESCRIPTION OF CONDITION
11 No Reference (Crank) N o distributor reference signal detected during engine

Signal at PCM cranking from the crankshaft position sensor.
13+** No change in MAP N o difference is recognized between the engine MAP

fromStart to Run reading and the barometric pressure reading at engine
start-up.
MAP Voltage too Low M A P sensor input below minimum acceptable voltage.
14+**
MAP Voltage too high
15 No vehicle speed N o speed sensor signal detected during road load

sensor signal. conditions.
17 Engine is cold too long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (thermostat).
21** O2S Shorted to Voltage Neither rich nor lean condition is detected from the oxygen
sensor input.
Oxygen sensor input voltage maintained above normal

operating range.
22+** ECT Coolant temperature sensor input below the minimum

acceptable voltage.
Voltage too High
or
ECT Coolant temperature sensor input above the maximum
Voltage too Low acceptable voltage.
23+** Intake A i r Temp Intake Manifold A i r Temperature Sensor input above the
Sensor Voltage High maximum acceptable voltage.
or
Intake A i r Temp Intake Manifold A i r Temperature Sensor input below the

Sensor Voltage Low minimum acceptable voltage.
24+** Throttle Position Sensor Throttle position sensor (TPS) input below the minimum
Voltage High acceptable voltage.
or
Throttle Position Sensor Throttle position sensor (TPS) input above the maximum
Voltage Low acceptable voltage.
+ Check Engine Lamp O n

* * Check Engine Lamp O n (California Only) J9314-134
DIAGNOSTIC TROUBLE CODE DESCRIPTION-CONTINUED
DIAGNOSTIC T R O U B L E CODE DRBII DISPLAY DESCRIPTION m CONDITION
25** Idle A i r Control Motor Circuits A shorted or open circuit detected in one
or more o f the Idle A i r Control motor circuits.
27+** Injector #1, # 2 , #3, #4, Injector output driver does not respond
#5 o r # 6 Circuits properly to the control signal.
33 A / C Clutch Relay Circuit A n open or shorted condition detected in the

A / C clutch relay circuit.
34 Speed Control Solenoid Circuits A n open or shorted condition detected in the

speed control vacuum o r vent solenoid circuits.
35 Radiator Fan Relay A n open o r shorted condition detected in

(XJ Only) radiator fan relay control circuit.
41+** Generator Field Not Generator field not switching properly.

Switching Properly
42 Auto Shutdown Relay A n open o r shorted condition detected in the

Control Circuit A S D relay control circuit.
or
N o A S D Relay Voltage N o A S D voltage sensed at PCM.
Sense at PCM
44 Battery Temp Sensor Battery temperature sensor voltage out of limit.

Voltage out o f limit
46+** Charging System Voltage too High Charging system voltage too high.
47+** Charging System Voltage too Low Charging system voltage too low.
51** 0 S stays below center (lean)

2
0 2 sensor signal stays lean.
52** O S stays above center (rich)

z
0 2 sensor signal stays rich.
53 Internal PCM Failure Internal Powertrain Control Module (PCM)

fault condition detected.
or
PCM Failure S P I N o internal communication between
Communication co-processors.
54 N o Cam Sync Signal at PCM N o sync pickup signal from camshaft position
sensor.
+Check Engine Lamp O n

**Check Engine Lamp O n (California Only)
J9314-148
DIAGNOSTIC TROUBLE CODE DESCRIPTION-CONTINUED
DIAGNOSTIC T R O U B L E CODE DRBII DISPLAY D E S C R I P T I O N OP CONDITION
62 PCM failure. Powertrain Control Module [PCM) failure -

SRI miles not stored Service Reminder Indicator (SRI) miles
not stored.
63 PCM Failure E E P R O M Powertrain Control Module (PCM) failure -

W r i t e Denied E E P R O M write denied.
76 Fule Pump Resistor A n open o r shorted condition detected in

(XJOnfy) Bypass Relay Circuit the ballast resistor bypass relay circuit
55 NA Completion o f diagnostic trouble code

display on the Malfunction Indicator Lamp
(Check Engine Lamp).
+Check Engine Lamp O n

**Check Engine Lamp O n (California Only)
J9314-149
M P I SYSTEM—COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Accelerator Pedal and Throttle Cable . 58 Fuel Tank Pressure Relief/Rollover Valve ...... 61
Air Cleaner Housing . . . . . . . . . . . . . . . . . . . . . . 58 Fuel Tanks 61
Air Conditioning (A/C) Clutch Relay 58 Fuel Tubes/Lines/Hoses and Clamps 61
Air Filter 58 Idle Air Control (IAC) Motor 61
Automatic Shut Down (ASD) Relay . . . . . . . . . . 58 Ignition Coil 62
Ballast Resistor Bypass Relay—XJ Models ..... 59 Intake Air Temperature Sensor 59
Ballast R e s i s t o r - X J Models 58 Intake Manifold 62
Brake Switch 59 Manifold Absolute Pressure (MAP) Sensor 62
Camshaft Position Sensor 59 Oxygen ( 0 ) Sensor
2 62
Crankshaft Position Sensor 60 Park Neutral Switch . 63
Engine Coolant Temperature Sensor 60 Power Steering Pressure Switch—2.5L Engine
Fuel Filter 60 Only 63
Fuel Injector 60 Powertrain Control Module (PCM) 63
Fuel Pump Module . 60 Quick-Connect Fittings 64
Fuel Pump Relay 60 Throttle Body 64
Fuel Rail Assembly 61 Throttle Position Sensor ( T P S ) 64
Fuel System Pressure Release Procedure 61 Vehicle Speed Sensor 65
ACCELERATOR PEDAL AND THROTTLE CABLE

Refer to the Accelerator Pedal and Throttle Cable
section of this group for removal/installation proce
dures.
AIR CONDITIONING (A/C) CLUTCH RELAY

The A/C clutch relay is located in the Power Dis
tribution Center (PDC) (Figs. 1 or 2). For location of
this relay within the PDC, refer to label attached to
bottom of PDC cover.
J9114-91

The ASD relay is located in the Power Distribution
Center (Figs. 1 or 2) (PDC). For location of this relay
within the PDC, refer to label attached to bottom of
PDC cover.
BALLAST RESISTOR-XJ MODELS

The fuel pump ballast resistor is located in the en
gine compartment on the left inner fender panel (Fig.
3). It is used on XJ models only.
AIR CLEANER HOUSING REMOVAL
Refer to Group 25, Emission Control System. (1) Disconnect wire connectors from ballast resistor
(Fig. 3).
AIR FILTER (2) Remove mounting screw and remove resistor
Refer to Group 25, Emission Control System. from vehicle.
J FUEL SYSTEM 14 - 5 !
(2) Install relay and its mounting screw. Tighten

screw to 8 N*m (76 in. lbs.) torque.
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
CAMSHAFT POSITION SENSOR

For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
INTAKE AIR TEMPERATURE SENSOR

The intake manifold air temperature sensor is in
stalled into the intake manifold plenum (Figs. 5 or
6).
Fig. 3 Fuel Pump Ballast Resistor—XJ Models

INSTALLATION
(1) Install ballast resistor and its mounting screw
to body. Tighten mounting screw to 2 N*m (20 in.
lbs.) torque.
CAUTION: Do not over tighten resistor mounting

screw. Damage to resistor body may result.
(2) Connect wire connectors to resistor.
BALLAST RESISTOR BYPASS RELAY-XJ MODELS

The ballast resistor bypass relay is located in the
engine compartment on a bracket connected to the
Power Distribution Center (PDC) (Fig. 4). It is used Fig. 5 Sensor Location—2.5L Engine
on XJ models only.
Fig. 4 Ballast Resistor Bypass Relay—XJ Models Fig. 6 Sensor Location—4.0L Engine
REMOVAL REMOVAL
(1) Disconnect the electrical connector from the
(1) Remove relay mounting screw.
sensor.
(2) Disconnect relay wiring connector and remove
(2) Remove the sensor from the intake manifold.
from vehicle.
INSTALLATION
INSTALLATION
(1) Install the sensor into the intake manifold.
(1) Connect relay to wiring connector. Tighten the sensor to 28 N»m ( 2 0 ft. lbs.) torque.
14-60 FUEL SYSTEM J
(2) Connect the electrical connector to the sensor.
CRANKSHAFT POSITION SENSOR

For description, operation and removal/installation
procedures, refer to Group 8D, Ignition Systems in
this manual.
ENGINE COOLANT TEMPERATURE SENSOR

The coolant temperature sensor is installed in the
thermostat housing (Fig. 7).
Fig. 8 Injector Retaining Clips

INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as
sembly and install retaining clip(s).
(2) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(3) Start engine and check for fuel leaks.
FUEL PUMP MODULE

Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
Fig. 7 Engine Coolant Temperature Sensor—Typical
FUEL PUMP RELAY
REMOVAL The Fuel Pump relay is located in the Power Dis
(1) Drain cooling system until the coolant level is tribution Center (PDC) (Figs. 9 or 10). For location of
below the cylinder head. Observe the WAENINGS this relay within the PDC, refer to label attached to
in Group 7, Cooling. bottom of PDC cover.
(2) Disconnect the coolant temperature sensor wire
connector.
(3) Remove the sensor from the thermostat hous
ing (Fig. 7).
INSTALLATION
(1) Install coolant temperature sensor into the cyl
inder block. Tighten to 28 N«m (21 ft. lbs.) torque.
(2) Connect the wire connector.
(3) Fill the cooling system. Refer to Group 7, Cool
ing System.
FUEL FILTER
FUEL INJECTOR
REMOVAL
(1) Remove the fuel rail. Refer to Fuel Rail Re
moval in this section. I
(2) Remove the clip(s) that retain the fuel injec
tors) to the fuel rail (Fig. 8).
(Fig. 11). Refer to Fuel Tubes/Lines/Hoses and

Clamps, or Quick-Connect Fittings. These can both
be found in the Fuel Delivery section of this group.
(7) Remove fuel rail mounting bolts.
On models with automatic transmissions, it may be
necessary to remove automatic transmission throttle
line pressure cable (and bracket). This will aid in
fuel rail assembly removal.
(8) Remove fuel rail by gently rocking until all the
fuel injectors are out of the intake manifold.
INSTALLATION
(1) Position tips of all fuel injectors into the corre
sponding injector bore in the intake manifold. Seat
J9114-91 injectors into manifold.
(2) Tighten fuel rail mounting bolts to 27 N-m (20
ft. lbs.) torque.
FUEL RAIL ASSEMBLY (3) Connect injector harness connectors to appro
priate (tagged) injector.
REMOVAL (4) Connect both fuel lines to fuel rail.
(5) Connect vacuum supply line to fuel pressure
WARNING: THE FUEL SYSTEM IS UNDER CON
STANT FUEL PRESSURE (EVEN WITH THE ENGINE regulator.
OFF) OF APPROXIMATELY 131-269 KPA (19-39 (6) Install protective cap to pressure test port fit
PSI). THIS PRESSURE MUST BE RELEASED BE ting.
FORE SERVICING THE FUEL RAIL (7) Install fuel tank cap.
(1) Remove fuel tank filler tube cap. (9) Start engine and check for fuel leaks.
(2) Disconnect the negative battery cable from bat
tery. FUEL SYSTEM PRESSURE RELEASE PROCEDURE
(3) Perform the Fuel System Pressure Release Pro
cedure as described in the Fuel Delivery System sec WARNING: THE FUEL SYSTEM IS UNDER A CON
tion of this Group. STANT PRESSURE (EVEN WITH THE ENGINE OFF)
(4) Remove and numerically attach a tag (if fuel OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
injector is not already tagged), the injector harness SERVICING THE FUEL PUMP, FUEL LINES, FUEL
connectors. Do this at each injector (Fig. 11). FILTER OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.

group. See Fuel Pressure Release procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re
moval/installation procedures.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE

Refer to the Fuel Tank section of this group for re
moval/installation procedures.
FUEL TUBES/LINES/HOSES AND CLAMPS

group for removal/installation procedures. Also refer
to Quick-Connect Fittings in the Fuel Delivery sec
Fig. 11 Fuel Injector Harness—Typical tion of this group.
(5) Disconnect vacuum line from fuel pressure reg
ulator (Fig. 11). IDLE AIR CONTROL (IAC) MOTOR
(6) Disconnect fuel supply tube from fuel rail and The IAC motor is mounted to the throttle body ad
the fuel return tube from fuel pressure regulator jacent to the throttle position sensor (Fig. 12).
REMOVAL
IAC motor.

OXYGEN (0 ) SENSOR
2
The 0 sensor is installed in the exhaust down pipe

2
Fig. 12 Idle Air Control just below the exhaust manifold flange (Fig. 14).
Motor—Removal/installation—Typical
REMOVAL
(2) Remove IAC motor torx head mounting screws.
(3) Remove IAC motor. WARNING: T H E E X H A U S T MANIFOLD B E C O M E S
V E R Y H O T DURING ENGINE O P E R A T I O N . A L L O W
INSTALLATION ENGINE T O COOL B E F O R E REMOVING OXYGEN
(1) Install IAC motor into throttle body and SENSOR.
tighten retaining screws.
(2) Connect electrical connector to IAC motor. (1) Raise and support the vehicle.
(2) Separate the electrical connectors.
IGNITION COIL (3) Remove the 0 sensor from the exhaust mani
2
Refer to Group 8D, Ignition Systems for removal/ fold.

installation procedures.
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
(Fig. 13).
REMOVAL
(1) Disconnect the MAP sensor electrical connector
(Fig. 13).
(2) Disconnect the MAP sensor vacuum supply
hose (Fig. 13).
(3) Remove the MAP sensor mounting screws and Fig. 14 Oxygen Sensor—Typical
remove MAP sensor.
INSTALLATION
INSTALLATION Threads of new factory oxygen sensors are coated
(1) Install MAP sensor to dash panel (and secure with anti-seize compound to aid in removal.
with mounting screws. (1) Install the 0 sensor into the exhaust manifold
2
(2) Install the MAP sensor vacuum supply hose. and tighten to 30 N-m (22 ft. lbs.) torque.
(2) Connect the 0 sensor wire connector to the
(3) Connect the MAP sensor electrical connector. 2
main harness.
PARK NEUTRAL SWITCH (4) Start the engine and again check power steer
Refer to Group 21, Transmissions for park neutral ing fluid. Add fluid if necessary.
switch service.
POWER STEERING PRESSURE SWITCH—2.5L On XJ models, the PCM is located in the engine
ENGINE ONLY compartment next to the air cleaner (Fig. 17). On YJ
The power steering pressure switch is installed in models, the PCM is located in the engine compart
the power steering high pressure hose (Figs. 15 or ment behind the windshield washer fluid reservoir
16). (Fig. 18).
PCM
Fig. 16 Power Steering Pressure Switch—XJ Models Fig. 18 PCM Location— YJ Models
REMOVAL REMOVAL
(1) Disconnect the negative battery cable at the
battery.
power steering pressure switch.
(2) YJ Models Only: Remove the windshield
(2) Place a small container or shop towel beneath
washer fluid bottle.
the switch to collect any excess fluid.
(3) Loosen the 60-Way connector mounting bolt
(3) Remove the switch.
(Figs. 17 or 18).
INSTALLATION (4) Remove the electrical connector by pulling
(1) Install the power steering switch. straight back.
(2) Connect the electrical connector to the switch. (5) Remove the three PCM mounting bolts.
(3) Check power steering fluid and add as neces (6) Remove PCM.
sary.
INSTALLATION THROTTLE
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro
sion, being spread apart, bent or misaligned. Also in
spect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Install PCM. Tighten three mounting bolts to 1
N»m (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting bolt to 4 N-m (35 in. lbs.) torque.
(4) YJ Models: Install windshield washer fluid bot
tle.
QUICK-CONNECT FITTINGS Fig. 20 Throttle

Refer to the Fuel Delivery System section of this Body—Removal/Installation—Typical
CAUTION: When the automatic transmission throttle
THROTTLE BODY cable i s connected, it M U S T be adjusted.
REMOVAL (4) If equipped with an automatic transmission,

(1) Disconnect the negative battery cable. connect and adjust the transmission line pressure ca
(2) Disconnect air cleaner hose from throttle body. ble. Refer to Group 21, Transmissions for adjustment
(3) Disconnect idle air control motor and throttle procedure.
position sensor wire connectors. (5) Install air cleaner hose to throttle body.
(4) Disconnect accelerator cable, throttle cable (au (6) Connect negative battery cable to battery.
tomatic transmission) and speed control cable (if
equipped) from throttle arm (Fig. 19). THROTTLE POSITION SENSOR (TPS)
The TPS is mounted to the throttle body (Figs. 21
or 22).
Fig. 19 Cables at Throttle Body

(5) Remove throttle body mounting bolts, throttle Fig. 21 TPS Location—2.5L Engine
body and gasket. Discard old gasket (Fig. 20).
(1) Disconnect TPS electrical connector.
INSTALLATION (2) Remove TPS mounting screws.
(1) Install throttle body and new gasket. Tighten (3) Remove TPS.
throttle body mounting bolts to 12 N-m (9 ft. lbs.)
torque. INSTALLATION
(2) Connect idle air control motor and throttle po The throttle shaft end of the throttle body slides
sition sensor wire connectors. into a socket in the TPS (Fig. 23). The TPS must be
(3) Connect throttle linkage to throttle arm. installed so that it can be rotated a few degrees. (If
Fig. 22 TPS Location—4.0L Engine

Fig. 24 Vehicle Speed Sensor— Typical
the sensor will not rotate, install the sensor with the (2) Disconnect the electrical connector from the
throttle shaft on the other side of the socket tangs). sensor.
The TPS will be under slight tension when rotated.
Fig. 23 Throttle Position Sensor—Installation

(1) Install the TPS and retaining screws.
(2) Connect TPS electrical connector to TPS.
(3) Manually operate the throttle (by hand) to
check for any TPS binding before starting the en Fig. 25 Sensor and Components
gine. (3) Remove (unscrew) the speedometer cable from
the sensor (Fig. 25).
VEHICLE SPEED SENSOR (4) Loosen the sensor mounting nut (Fig. 25).
The vehicle speed sensor (Fig. 24) is located on the (5) Remove the sensor.
extension housing of the transmission on 2WD mod
els. It is located on the transfer case on 4WD models. INSTALLATION
(1) Install new sensor into speedometer adapter.
REMOVAL (2) Tighten sensor mounting nut.
(1) Raise and support vehicle. (3) Connect electrical connector to sensor.
(4) Connect the speedometer cable.
14 - 66 FUEL SYSTEM
SPECIFICATIONS
GENERAL INFORMATION TORQUE
The following specifications are published from the
DESCRIPTION TORQUE
tion. If anything differs between the specifica
tions found on the Vehicle Emission Control Accelerator Pedal Bracket
Information (VECI) label and the following spec Mounting Nuts 4 N-m ( 3 6 in. lbs.)
ifications, use specifications on VECI label. The Ballast Resistor (XJ Fuel Pump) 2 N-m ( 2 0 in. lbs.)
VECI label is located in the engine compartment.
Ballast Resistor Bypass Relay (XJ)................... 8 N-m ( 7 6 in. lbs.)
FUEL TANK CAPACITIES Intake Manifold A i r Temperature

Sensor 2 8 N-m ( 2 0 ft. lbs.)
Engine Coolant Temperature Sensor 2 8 N-m (21 ft. lbs.)

IUEL TANK GALLONS* LITERS*
PCM Mounting Screws 1 N-m (9 in. lbs.)
XJ 20.02 76
PCM 6 0 - W a y Connector Screw 4 N-m ( 3 5 in. lbs.)
YJ 20.0 76 Fuel Filter Retaining Strap 1 2 N-m ( 1 0 6 in. lbs.)
YJ 15.0 57 Fuel Pump/Gauge Send. Unit-
*Nominal refill capacities are shown. A variation may be to-Fuel Tank Screws (YJ) 2 N-m ( 1 8 in. lbs.)
observed from vehicle to vehicle due to manufacturing
Fuel Pump Line N u t . . . . . 2 5 N-m (18 ft. lbs.)
tolerances, ambient temperature and refill procedure.
Fuel Rail Mounting Bolts 2 7 N-m ( 2 0 ft. lbs.)
J9314-143
Fuel Tank Mounting Strap N u t (XJ) 11 N-m ( 1 0 0 in. lbs.)
Fuel Tank Skid Plate (YJ) 7 N-m ( 6 5 in. lbs.)

FUEL SYSTEM
Fuel Tank Mounting Strap N u t (YJ) 1 8 N-m (13 ft. lbs.)
Oxygen Sensor 3 0 N-m ( 2 3 ft. lbs.)

COMPONENT RATING
Throttle Body Mtg. Bolts 1 2 N-m (9ft.lbs.)
MPI Fuel System Pressure (with J9314-155
vacuum applied to regulator) 2 1 4 k P a ( 3 1 psi)
MPI Fuel System Pressure (without

vacuum applied to pressure
regulator) 2 6 9 - 2 7 6 kPa ( 3 9 - 4 1 psi)
MPI Fuel System Pressure Drop

(fuel pump not engaged) U p to 1 3 8 kPa ( 2 0 psi)
Pressure-Vacuum Filler Cap Relief.. 10 kPa ( 1 . 5 psi) pressure

6 kPa (1.8 in. Hg) vacuum
J9314-154
PROPELLER SHAFTS 16 - 1
PROPELLER SHAFTS
CONTENTS
page page
GENERAL INFORMATION 1 TORQUE SPECIFICATIONS 14

PROPELLER SHAFT REPLACEMENT 7 UNIVERSAL JOINT REPLACEMENT . 9
SERVICE DIAGNOSIS/PROCEDURES 3
GENERAL INFORMATION
PROPELLER SHAFTS will prevent the undercoating from causing an
The function of a propeller shaft is to transmit unbalanced condition and vibration.
power from one point to another. The shaft is de
signed to send torque from the transmission (transfer CAUTION: Use e x a c t replacement hardware for at
case on 4 W D vehicles) to the axle (Fig. 1, 2 ) . taching the propeller shafts. T h e s p e c i f i e d t o r q u e
The propeller shaft must operate through con must always be applied w h e n tightening the fasten
stantly changing relative angles between the trans ers.
mission and axle. It must also be capable of changing
length while transmitting torque. The axle rides sus
pended by springs in a floating motion. The prop- UNIVERSAL JOINTS
shaft must be able to change operating angles when Two different types of U-joints are used with the
going over various road surfaces. This is done propeller shafts:
through universal joints, which permit the propeller • Single cardan U-joint (Fig. 3 )
shaft to operate at different angles. The slip joints (or • Double cardan U-joint (Fig. 4)
yokes) permit contraction or expansion (Fig. 1, 2).
Tubular propeller shafts are balanced by the man LUBRICATION
ufacturer with weights spot welded to the tube. The slip yoke and certain universal joints are
The propeller shaft is designed and built with the equipped with zerk type lubrication fittings. They
yoke lugs in line with each other which is called phas should be lubricated with a multi-purpose NLGI
ing. This design produces the smoothest running condi Grade 2 EP lubricant. All U-joints should be in
tion, an out of phase shaft can cause a vibration. spected for leakage and damage each time the vehi
Before undercoating a vehicle, the propeller cle is serviced. If seal leakage or damage exists, the
shaft and the U-joints should be covered. This U-joint should be replaced.
PINION TRANSFER
YOKE CASE
REAR AXLE
FRONT AXLE
STRAP
SCREW
SUP YOKE J9216-1
Fig. 1 Propeller Shafts (XJ Vehicles)

16 - 2 PROPELLER SHAFTS J
FRONT AXLE PINION TRANSFER REAR

YOKE CASE AXLE
SINGLE CARDAN
U-JOINT
FRONT
DRIVE SHAFT
STRAP
SCREW
STRAP SLIP Y O K E ^ REAR DRIVE SHAFT SCREW J9216-15
Fig. 2 Propeller Shafts (YJ Vehicles)
BEARING
CAP
NEEDLE
BEARING
SPIDER
NEEDLE
BEARING
BEARING
CAP
1. LINK YOKE
2. SOCKET SPRING
3. SOCKET BALL RETAINER
YOKE 4. THRUST WASHER
5. NEEDLE BEARINGS
6. SEAL
RETAINING 7. BEARING CAP
CLIP J9216-4
8. REAR SPIDER
9. SOCKET YOKE
Fig. 3 Single Cardan Universal Joint 10. SOCKET BALL
11. FRONT SPIDER
12. SOCKET NEEDLE BEARINGS
13. THRUST WASHER
14. DRIVE S H A F T YOKE
15. RETAINING CLIP J8916-2
Fig. 4 Double Cardan (CV) Universal Joint

J PROPELLER SHAFTS 16 - 3
SERVICE DIAGNOSIS/PROCEDURES
INDEX
page page
Runout . 4 Universal Joint Angle Measurement 4
Unbalance . 3 Vibration 3
VIBRATION • Inspect the propeller shaft for missing balance

Tires that are out-of-round or wheels that are un weights, broken welds, and bent areas. If the pro
balanced will cause a low frequency vibration. Refer peller shaft is bent, it must be replaced.
to Group 2 2 , Wheels and Tires for additional infor • Ensure the universal joints are not worn, are prop
mation. erly installed, and are correctly aligned with the
Brake drums that are unbalanced will cause a shaft.
harsh, low frequency vibration. Refer to Group 5, • Check the universal joint clamp screws torque
Brakes for additional information. (1) Raise the vehicle.
Driveline vibration can also result from loose or (2) Remove the wheel and tires. Install the wheel
damaged engine mounts. Refer to Group 21, Trans lug nuts to retain the brake drums.
missions for additional information. (3) Mark and number the shaft six inches from the
Propeller shaft vibration will increase as the vehi yoke end at four positions 90° apart.
cle speed is increased. A vibration that occurs within (4) Run and accelerate the vehicle until vibration
a specific speed range is not caused by propeller shaft occurs. Note the intensity and speed the vibration oc
unbalance. Defective universal joints or an incorrect curred. Stop the engine.
propeller shaft angle are usually the cause. (5) Install a screw clamp at position 1 (Fig. 1).
(6) Start the engine and re-check for vibration. If
UNBALANCE there is little or no change in vibration, move the
If propeller shaft unbalance is suspected, it can be clamp to one of the other three positions. Repeat the
verified with the following procedure. vibration test.
Removing and re-indexing the propeller shaft (7) If there is no difference in vibration at the
180° may eliminate some vibrations. other positions, the vibration may not be propshaft
• Clean all the foreign material from the propeller unbalance.
shaft and the universal joints.
DRIVELINE VIBRATION
D r i v e Condition Possible Cause Correction

PROPELLER SHAFT a. Undercoating or other foreign material a. Clean exterior of shaft and wash with
on shaft. solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or excessive c. Install replacement yoke.
runout.
d. Incorrect drive line angularity. d. Correct angularity
e. Rear spring center bolt not in seat. e. Loosen spring U-bolts and seat center
bolts.
Worn U-joint bearings. f. Replace U-joint.
Propeller shaft damaged (bent tube) or g. Install replacement propeller shaft.
out of balance.
Broken rear spring. h. Replace rear spring.
Excessive runout or unbalanced i. Reindex propeller shaft 180°, test and
condition. correct as necessary.
I- Excessive drive pinion gear shaft yoke j. Reindex propeller shaft 180° and
runout. evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
J9216-7
(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.
RUNOUT
(1) Remove dirt, rust, paint, and undercoating
SCREWDRIVER from the propeller shaft surface. Areas where the
dial indicator will contact the shaft must be clean.
(2) The dial indicator must be installed perpendic
RF487 ular to the shaft surface.
(3) Measure runout at the center and ends away
Fig. 1 Clamp Screw At Position 1 from welds.
(4) Refer to Runout Specifications chart.
(8) If the vibration decreased, install a second
(5) Replace the propeller shaft if the runout ex
clamp (Fig. 2) and repeat the test.
ceeds the limit.
RUNOUT SPECIFICATIONS
Front o f shaft . 0 . 0 1 0 i n . ( 0 . 2 5 mm)
Center o f shaft 0 . 0 1 5 i n . ( 0 . 3 8 mm)
Rear o f shaft 0 . 0 1 0 in. ( 0 . 2 5 mm)
N O T E : Measure front/rear runout approximately 3 inches

( 7 6 mm) from the weld seam at each end o f the shaft tube
f o r tube lengths over 3 0 inches. U n d e r 3 0 inches the max.
runout is 0 . 2 0 inch f o r full length o f the tube.
J9116-15
RF488 UNIVERSAL JOINT ANGLE MEASUREMENT

Fig. 2 Two Clamp Screws At The Same Position INFORMATION
(9) If the clamps cause an additional unbalance, When two shafts come together at any common
separate the clamps (1/4 inch above and below the joint, the bend that is formed is called the operating
mark). Repeat the vibration test (Fig. 3). angle. The larger the angle, the larger the amount of
acceleration and deceleration of the joint. This speed
Vi INCH ing up and slowing down of the joint must be can
celled to produce a smooth power flow. This is done
through phasing and proper universal joint working
angles.
A propeller shaft is properly phased when the yoke
ends are on the same plane or in line. A twisted
shaft will throw the yokes out of phase and cause a
noticeable vibration.
When taking universal joint angle measurements
or checking phasing with two piece shafts, consider
each shaft separately. On 4WD vehicles, the front
shaft input (pinion shaft) angle has priority over the
caster angle.
Ideally the driveline system should have;
RF489 • Angles that are in equal or opposite within 1 de
gree of each other
Fig. 3 Clamp Screws Separated • Have a 3 degree maximum operating angle
• 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. 4).
PROPELLER SHAFT MAX. NORMAL

R.P.M. OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5°
2500 7°
2000 8°
1500 11°
J9316-4
Fig. 4 Maximum Angles and R.P.M.

INSPECTION
Before measuring universal joint angles, the Fig. 5 Front (Output) Angle Measurement (A)
following must be done.
• Inflate all tires to correct pressure
• Check angles in the same loaded or unloaded con
dition as when the vibration occurred. Propshaft an
gles will change according to the amount of load in
the vehicle. Always check angles in loaded and un
loaded conditions.
• Check the condition of all suspension components
and verify all fasteners are torqued to specifications.
• Check the condition of the engine and transmis
sion mounts and verify all fasteners are torqued to
specifications.
MEASUREMENT
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
J9216-9
universal joint so protractor base sits flat.
(1) Rotate the shaft until transmission/transfer Fig. 6 Propeller Shaft Angle Measurement (C)
case output yoke bearing is facing downward.
(4) Subtract smaller figure from larger (C minus
Always make measurements from front to A) to obtain transmission OUTPUT OPERATING
rear.
ANGLE.
(2) Place Inclinometer on yoke bearing (A) parallel
(5) Rotate propeller shaft 90 degrees and place In
to the shaft (Fig. 5). Center bubble in sight glass and
clinometer on pinion yoke bearing parallel to the
record measurement.
shaft (Fig. 7). Center bubble in sight glass and record
This measurement will give you the transmis measurement.
sion or OUTPUT YOKE ANGLE (A).
This measurement will give you the pinion
(3) Rotate propeller shaft 90 degrees and place In shaft or INPUT YOKE ANGLE (B).
clinometer on yoke bearing parallel to the shaft (Fig.
(6) Subtract smaller figure from larger (C minus
6). Center bubble in sight glass and record measure
B) to obtain axle INPUT OPERATING ANGLE.
ment. This measurement can also be taken at the
Refer to rules given below and the example in (Fig.
rear end of the shaft.
8) for additional information.
This measurement will give you the PROPEL
LER SHAFT ANGLE (C).
16 - 6 PROPELLER SHAFTS
ADJUSTMENT AT AXLE WITH LEAF SPRINGS

J
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.
PINION YOKE
BEARING CAP
SPECIAL
TOOL
7663
(J-23498A) J9216-12
RH463
Fig. 7 Rear (Input) Angle Measurement (B)
• Good cancellation of u-joint operating angles (with Fig. 9 Angle Adjustment at Leaf Springs
in 1°)
• Operating angles less than 3 °
• At least 1/2 of one degree continuous operating
(propeller shaft) angle
Output
Yoke
H o r i z o n t a l Level
(A) O u t p u t Yoke = 3 . 0 ° f 4.9° (B) A x l e Input Yoke - 3.2° o r 4.9°

r
(C) P r o p . S h a f t . 4.9° O f
-3.0° (C) Prop. S h a f t = 4.9° ° -3.2°
Transmission O u t p u t 1.9° A x l e Input 1.7°

Operating Angle Operating Angle
Trans. Output Operating Angle 1.9°

A x l e Input O p e r a t i n g A n g l e -1.7°
A m o u n t o f U-Jdint Cancellation 0.2°

J9316-3
Fig. 8 Universal Joint Angle Example

PROPELLER SHAFTS 16 - 7
J ADJUSTMENT—XJ FRONT SHAFT
Adjust the pinion gear angle at the lower suspen
sion arms with shims (Fig. 10). Adding shims will
decrease the pinion gear shaft angle but will increase
the caster angle. The pinion gear shaft angle has pri
ority over the caster angle.
J8916-22
Fig. 10 Angle Adjustment—XJ Vehicles
PROPELLER SHAFT REPLACEMENT

PRECAUTIONS CAUTION: It is very important to protect the ma
Use exact replacement hardware for attaching the chined, external surface of the slip yoke from dam
propeller shafts. Exact replacement will ensure safe age after propeller shaft removal. If damaged, the
operation. The specified torque must always be ap transmission extension seal could be damaged and
plied when tightening the fasteners. c a u s e a leak.
Put reference marks on the propshaft yoke and
axle or transmission yoke before service (Fig. 1). This
will assure correct phasing and eliminate possible vi FRONT-XJ VEHICLES
bration. REMOVAL
REFERENCE MARKS (1) Raise the vehicle.
(2) Scribe alignment marks on the yokes at the
transfer case. Place marks at the pinion shaft and at
each end of the propeller shaft. These marks will be
used for installation reference (Fig. 2).
(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Disconnect the propeller shaft at the transfer
case and remove the propeller shaft.
INSTALLATION
(1) Position the propeller shaft with the yoke ref
erence marks aligned (Fig. 1). Install the propeller
shaft.
J9316-2
Replacement U-joint straps and bolts must be
Fig. 1 Reference Marks on Yokes installed.
(2) Tighten the U-joint strap/clamp bolts at the
CAUTION: Do not allow the propeller shaft to drop #
axle yoke to 19 N m (14 ft. lbs.) torque.
or hang from either universal joint during removal. (3) Tighten the flange to transfer case bolts to 27
Attach it to the vehicle underside with wire to pre N*m (19.5 ft. lbs.) torque.
vent damage to the universal joints. (4) Lower the vehicle.
11-8 PROPELLER SHAFTS J
FRONT LUBE CV-JOINT SLIDING

AXLE FITTING COUPLER
SCREW
SCREW & 19 N-m
WASHER J92164 (14 ft-lbs). CLAMP J9216-6
Fig. 2 Front Propeller Shaft Fig. 3 Rear Propeller Shaft

R E A R - X J J J VEHICLES
REMOVAL
(1) Shift the transmission and transfer case (if ap
plicable) to their Neutral positions. Raise the vehicle.
(2) Scribe alignment marks at the pinion shaft and
at each end of the propeller shaft. These marks will
be used for installation reference.
shaft yoke.
(4) Slide the slip yoke off of the transmission/
transfer case output shaft and remove the propeller
shaft (Fig. 3).
FRONT 19 N.m TRANSFER
J9216-3 YOKE (14 ft. lbs.) CASE
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer Fig. 4 YJ Front Propeller Shaft
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller shaft yoke.
shaft (Fig. 3). (4) Disconnect the propeller shaft at the transfer
Replacement U-joint straps and bolts must be case and remove the propeller shaft.
installed.
(2) Tighten the U-joint strap/clamp bolts at the INSTALLATION
axle yoke to 19 N*m (14 ft. lbs.) torque. (1) Position the propeller shaft with the reference
(3) Lower the vehicle. marks aligned (Fig. 4). Install the propeller shaft.
Replacement U-joint straps and bolts must be
FRONT—YJ VEHICLES installed.
(2) Tighten the U-joint strap/clamp bolts at the
REMOVAL e
axle yoke to 19 N m (14 ft. lbs.) torque.
(1) Raise the vehicle. (3) Tighten the U-joint strap/clamp to transfer case
(2) Scribe alignment marks on the yokes at the bolts to 27 N«m (19.5 ft. lbs.) torque.
transfer case. Place marks at the pinion shaft and at (4) Tighten the U-joint strap bolts to 19 N*m (14 ft.
each end of the propeller shaft. These marks will be lbs.) torque.
used for installation reference (Fig. 4). (5) Lower the vehicle.
J PROPELLER SHAFTS 16-9
UNIVERSAL JOINT REPLACEMENT

PRECAUTIONS (5) Set the yoke in an arbor press or vise with a large
It is very important to put reference marks on the socket beneath it. Position the yoke with the lube fit
yokes before removal or component service (Fig. 1). ting pointing up (if equipped). Place a smaller socket on
This will assure correct phasing and eliminate possi the upper bearing assembly and press it through to re
ble vibration. lease the lower bearing assembly (Fig. 3 ) .
REFERENCE MARKS
J9316-2
Fig. 1 Reference Marks on Yokes

SINGLE CARDAN
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller Fig. 3 Press Out Bearing
Shaft Replacement in this Group. (6) If the bearing assembly will not pull out by
(2) Paint or score alignment marks on the yokes hand after pressing, tap the base of the lug near it to
and propeller shaft for installation reference. dislodge.
(3) Using a soft drift, tap the outside of the bear (7) To remove the opposite bearing, turn the yoke
ing assembly to loosen snap ring. over and straighten the cross in the open hole. Then
(4) Remove snap rings from both sides of yoke carefully press the end of the cross until the remain
(Fig. 2). ing bearing can be removed (Fig. 4).
CAUTION: If the cross or bearing assembly are

cocked when being pressed, the bearing assembly
will score the walls of the yoke bore and ruin the
yoke.
CLEANING AND INSPECTION

(1) Clean all the universal joint yoke bores with
cleaning solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBL Y/INSTALLA TION

(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
(2) Position the cross in the yoke with its lube fit
ting (if equipped) pointing up (Fig. 5 ) .
(3) Place a bearing assembly over the trunnion
Fig. 2 Remove Snap Ring and align it with the cross hole (Fig. 6 ) . Keep the
16-10 PROPELLER SHAFTS
J
BEARING
J9316-24 Fig. 6 Install Bearing On Trunnion

Fig. 4 Press Out Remaining Bearing
DOUBLE CARDAN (CV)
CROSS
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Paint or score alignment marks on the
yokes and propeller shaft for installation refer
ence.
( 3 ) Remove all the bearing assembly snap rings
(Fig. 7).
( 4 ) Press the bearing assembly partially from the
outboard side of the center yoke, enough to grasp by
J9316-22
Fig. 5 install Cross in Yoke
needle bearings upright in the bearing assembly. A
needle roller lying at the bottom will prevent proper
assembly.
( 4 ) Press the bearing assembly into the cross hole
enough to install a snap ring. Install a snap ring.
( 5 ) Repeat steps 3 and 4 to install the opposite
bearing assembly. If the joint is stiff, strike the yoke
with a soft hammer to seat the needle bearings. In
stall a snap ring.
(6) Add grease to lube fitting (if equipped).
(7) Install the propeller shaft. Refer to Propeller J9316-5
Shaft Replacement in this Group. Fig. 7 Remove Snap Rings
vise jaws (Fig. 8 ) . Be sure to remove any lube fittings

that may interfere with removal.
J9316-8
Fig. 10 Remove Centering Kit

J9316-6 CLEANING AND INSPECTION
(1) Clean all the U-joint yoke bores with cleaning
Fig. 8 Press Out Bearing solvent and a wire brush.
(5) Grasp the protruding bearing by vise jaws. Tap (2) Inspect the yokes for distortion, cracks and
the tube yoke with a mallet and drift to dislodge worn bearing assembly bores.
from the yoke (Fig. 9).
ASSEMBLY/INSTALLATION
During installation, ensure that the spiders
and yokes are aligned to the reference marks.
(1) Fit a cross into the tube yoke (Fig. 11).
J9316-9
Fig. 9 Remove Bearing From Yoke Fig. 11 Install Cross In Yoke

(6) Flip assembly and repeat steps 4 and 5 for re (2) Place a bearing assembly in a tube yoke hole
moving the opposite side bearing. This will then al and over a trunnion. Keep the needle bearings up
low removal of the cross centering kit assembly and right in the bearing assembly (Fig. 12). A needle
spring (Fig. 10). roller lying at the bottom will prevent proper assem
(7) Press the remaining bearing assemblies out the bly. Be sure to remove any lube fittings that may in
other cross as described above to complete the disas terfere with removal.
sembly.
J9316-10
J9316-12
Fig. 12 Install Bearing Assembly
(3) Press the bearing assembly in place and install Fig. 14 Press In Bearing Assembly
a snap ring (Fig. 13).
Fig. 15 Install Center Yoke

(7) Place two bearing assemblies on the remaining
cross (opposite sides). Fit the open trunnions into the
Fig. 13 Press In Bearing Assembly center yoke holes and the bearing assemblies into
(4) Flip the tube yoke and bearing assembly instal the centering kit (Fig. 17). Align the lube fitting on
lation on the opposite trunnion. Install a snap ring the cross with the other two lube fittings.
(Fig. 14). (8) Press the remaining two bearing assemblies
into place and install snap rings (Fig. 18).
(5) Fit the center yoke on the remaining two trun
(9) Tap the snap rings to allow them to seat into
nions and press bearing assemblies in place, both
the grooves (Fig. 19).
sides (Fig. 15). Install a snap ring. (10) Check for proper assembly. Flex the CV joint
(6) Install the centering kit assembly inside the beyond center, it should snap over-center in both di
center yoke making sure the spring is in place (Fig. rections when correctly assembled (Fig. 20).
16). Align the lube fitting on the centering kit with (11) Add grease to all three lube fittings.
the lube fitting on the installed cross. (12) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
PROPELLER SHAFTS 16-13
Fig. 19 Seat Snap Rings In Groove

16 • 14 PROPELLER SHAFTS
PROPELLER SHAFTS AND U-JOINTS
DESCRIPTION TORQUE
Double Cardan to Transfer

Case Yoke Bolts 26 N m (19.5 ft. lbs.)
Single Cardan Clamp Bolt to
Axle Yoke 19 N-m (14 ft. lbs.)
J9316-31
J STEERING 19-1
STEERING
CONTENTS
page page
GENERAL INFORMATION 1 STEERING COLUMN GENERAL SERVICE . . . . 45

MANUAL STEERING GEAR 35 STEERING LINKAGE- XJ 14
NON-TILT STEERING COLUMN 50 STEERING LINKAGE-YJ 17
POWER STEERING PUMP 9 TILT STEERING COLUMN 59
POWER STEERING SYSTEM DIAGNOSIS 3 TORQUE SPECIFICATIONS 69
RECIRCULATING BALL POWER STEERING GEAR . 19
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS plied by the pump. Manual steering is always avail
Jeep vehicles can have either a manual or power able at times when the engine is not running or in
steering system (Fig. 1). A recirculating-ball type the event of pump or belt failure. Steering effort is
steering gear is used for both systems. higher under such conditions.
Power steering systems use; The steering stub shaft, rotary valve, worm shaft,
• Steering gear and rack piston assembly are all in line. All oil pas
• Pressure and return fluid hoses and fittings sages are internal within the gear housing except for
• Belt driven steering pump the pressure and return hoses between the gear and
• Integral or remote body mounted pump reservoir the pump.
MANUAL POWER The power steering gear has a recirculating ball
GEAR FLUID HOSE system. This acts as a rolling thread between the
GEAR CONNECTION
worm shaft and rack piston. The worm shaft is sup
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned right, the rack piston moves up in
gear. Turning the worm shaft left moves the rack
piston down in gear. The rack piston teeth mesh with
the sector, which is part of the pitman shaft. Turning
the worm shaft turns the pitman shaft, which turns
the wheels through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack piston is assisted by hydraulic pressure. If
J9219-20
the steering system loses hydraulic pressure, the ve
Fig. 1 Steering Gears hicle can be controlled manually, but with higher
steering effort.
POWER STEERING GEAR An identification code located on the side cover des
The steering gear is mounted on the left frame rail. ignates the gear ratio (Fig. 2).
The gear is joined to the intermediate shaft by a uni • Code BH designates 14:1 ratio used in XJ vehicles
versal joint coupling. The coupling helps isolate noise • Code BF designates 13-16:1 ratio used in YJ vehi
and road shock from the interior. cles
The major internal components of the gear are the: A recirculating-ball steering gear is used with the
• Rotary valve assembly
power (assisted) steering system (Fig. 1). The power
• Steering worm shaft
steering gear can be adjusted and internally serviced.
• Rack piston assembly
• Pitman shaft POWER STEERING PUMP
The movement of these parts, while turning or Hydraulic pressure is provided for operation of the
parking, is aided by hydraulic pressure and flow sup power steering gear by a belt driven power steering
19 - 2 STEERING J
INDENTIFICATION
Fig. 2 Ratio Code Location

pump. The power steering pump is a constant flow
rate and displacement, vane-type pump. The internal
parts in the housing operate submerged in fluid. The
flow control orifice is part of the high pressure line
fitting. The pressure relief valve inside the flow con Fig. 3 TC Series Pump With Integral Reservoir
trol valve limits the pump pressure.
Because of the different pressure rates, power
steering pumps are not interchangeable with
pumps installed in other vehicles.
The power steering pump is connected to the steer
ing gear via high pressure and return hose. The
pump shaft has a pressed-on drive pulley that is belt
driven by the crankshaft pulley (Fig. 3).
XJ vehicles with 2.5L engines and all YJ vehicles:
The reservoir is mounted at the front left side of the
engine compartment. XJ vehicles equipped with a
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 J8919-7
column (Fig. 4).
The ignition key/lock cylinder is located in the Fig. 4 Steering Columns
steering column. When the key/lock cylinder is The center, slip-type intermediate shaft is attached
turned to the LOCK position, the ignition switch and to the steering gear and steering column shaft with
steering shaft cannot be operated. For vehicles with universal joints.
an automatic transmission, the lock mechanism also Both types of steering columns have anti-theft pro
prevents operation of the gear shift mechanism. visions. They are energy-absorbing.
STEERING 19 - 3
J POWER STEERING SYSTEM DIAGNOSIS
PUMP PRESSURE TEST CAUTION: The following test procedure involves
( 1 ) Check belt tension and adjust as necessary. testing maximum pump pressure output and flow
(2) Disconnect high pressure hose at gear or pump. control valve operation. Do not leave valve closed
Use a container for dripping fluid. for more than 5 seconds as the pump could be
(3) Connect Gauge 7617 (J21567) to both hoses us damaged.
ing adapter fitting (Fig. 1). Connect spare pressure
hose to gear or pump. (8) Close valve fully three times and record high
est pressure indicated each time. All three readings
SPECIAL
must be above specifications and within 345 kPa
(50 psi) of each other.
• Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
• Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
CAUTION: Do not force the pump to operate against

the stops for more than 2 to 4 seconds at a time.
Pump damage will result.
(9) Open the test valve, turn steering wheel ex

1 Pressure Hose to Steering Gear treme left and right positions against the stops.
2 Shut-Off \farve
3 Pressure Hose From ftimp J9219-43 Record the highest indicated pressure at each posi
tion. Compare readings to specifications. If highest
Fig. 1 Pressure Test Gauge output pressures are not the same against either
(4) Open the test valve completely. stop, the gear is leaking internally and must be re
(5) Start engine and let idle. paired.
(6) Check fluid level, add fluid as necessary.
(7) Gauge should read below 862 kPa (125 psi), if PUMP OPERATING SPECIFICATIONS
above, inspect the hoses for restrictions and repair as
VEHICLE R E L I E F P R E S S U R E (P.S.I.) ± 5 0
necessary. The initial pressure should be in the
range of 345-552 kPa (50-80 psi). YJ 1050
XJ 1400
J9319-89
19-4 STEERING J
POWER STEERING SYSTEM DIAGNOSIS
PROBLEM P O S S I B L E CAUSE CORRECTION
Objectionable N o i s y r e l i e f v a l v e i n t h e hy dr a ul i c T h e r e is some noise in all p o w e r steering

"Him" pump. Steering gear valve noise is systems. O n e o f the most common is a hiss
t r a n s m i t t e d t h r o u g h t h e s t e e r i n g col i n g s o u n d m o s t e v i d e n t at standstill p a r k i n g .
u m n o r o p e n a i r passages i n t h e a r e a H i s s i s a h i g h f r e q u e n c y n o i s e , that i s p r e
w h e r e t h e c o l u m n o r c o n t r o l s pass s e n t i n e v e r y v a l v e a n d r e s u l t s from h i g h
t h r o u g h t h e f l o o r i n t o e n g i n e compart velocity f l u i d p a s s i n g v a l v e o r i f i c e edges.
ment. T h e r e is no relationship between this noise
and performance o f the steering. D o not
replace t h e i n t e r m e d i a t e s h a f t o r gear u n l e s s
t h e h i s s i s e x t r e m e l y objectionable. Check
the dashboard seals between the drivers
area and under hood to eliminate open
spaces.
R a t t l e O r Chuckle 1. G e a r loose on the f r a m e . 1. Check the gear mounting bolts. T o r q u e the

Noise I n S t e e r i n g bolts t o specifications.
Gear 2. Steering linkage looseness. 2. Check linkage pivot points f o r w e a r . Replace
if necessary.
3. Pressure hose touching o t h e r p a r t s o f 3. A d j u s t the hose position. D o not bend tubing
vehicle. by h a n d .
4. Loose pitman a r m . 4. T o r q u e the pitman a r m bolt.
5. I m p r o p e r over-center adjustment. A 5. A d j u s t to specifications.
slight rattle may occur o n t u r n s because
of increase clearance o f f the " h i g h
p o i n t / ' T h i s i s n o r m a l a n d clearance
must not be reduced b e l o w specified
limits t o eliminate this slight r a t t l e .
J9319-65
STEERING 19 - 5
PROBLEM POSSIBLE CAUSE CORRECTION
Excessive W h e e l 1. A i r in the system. 1 . A d d oil t o the pump r e s e r v o i r a n d bleed.

Kick-Back Or Check hose connectors f o r p r o p e r t o r q u e .
Loose Steering 2 . S t e e r i n g g e a r mounting loose. 2 . T i g h t e n attaching bolts t o specified t o r q u e .
3 . S t e e r i n g linkage joints w o r n . 3 . Replace loose p a r t s .
4 . F r o n t wheel bearings incorrectly 4 . A d j u s t the bearings o r replace w i t h n e w
adjusted o r w o r n . p a r t s as necessary.
5 . S t e e r i n g g e a r i m p r o p e r l y adjusted. 5 . A d j u s t t o specifications.
6 . W o r n o r missing poppet valve (steering 6 . Replace the poppet valve.
gear).
7 . D a m a g e d o r w o r n steering gear. 7. Disassemble a n d r e p a i r the steering gear as
outlined in the unit r e p a i r manual.
Vehicle Leads T o 1. F r o n t end misaligned. 1 . A d j u s t t o specifications.

One Side O r The 2. Unbalanced steering gear valve. I f this 2. Replace the g e a r valve.
Other (Keep i n is the cause, steering effort w i l l be v e r y
Mind The Road light in direction o f lead a n d heavy in
And W i n d opposite direction.
conditions). Test 3 . S t e e r i n g shaft r u b b i n g the I D o f the 3 . A l i g n the column.
The V e h i c l e , shaft tube.
G o i n g in Both 4 . S t e e r i n g linkage not level. 4 . Adjust as required.
Directions, On A
Flat Road.
Momentary 1. L o w oil level in the pump. 1 . A d d p o w e r steering f l u i d as r e q u i r e d .

Increase I n Effort 2 . Pump belt s l i p p i n g . 2 . T i g h t e n o r replace belt.
When T u r n i n g The 3 . H i g h internal leakage (steering gear o r 3. Refer to "Pump Pressure Test" in
Wheel Q u i c k l y To pump). this section.
The R i g h t O r Left
Poor Return O f 1 . T i r e s under-inflated. 1. Inflate t o specified p r e s s u r e .

Steering 2 . L o w e r coupling flange r u b b i n g against 2. Loosen the pinch bolt a n d assemble
the steering g e a r adjuster p l u g . properly.
3 . S t e e r i n g wheel r u b b i n g against 3 . A d j u s t the steering jacket.
directional signal housing.
4 . T i g h t o r f r o z e n steering shaft bearings. 4 . Replace the b e a r i n g s .
5 . S t e e r i n g linkage o r ball joints b i n d i n g . 5 . Replace the affected p a r t s .
6 . S t e e r i n g g e a r t o column misalignment. 6 . A l i g n the steering column.
7 . T i e r o d pivots not centralized. 7 . A d j u s t tie r o d ends a s required t o center
pivots.
8. Lack o f lubricant in the suspension ball 8. Lubricate. Refer to G r o u p O -
joints a n d the steering linkage. Lubrication and Maintenance.
9 . Stuck o r plugged spool valve. 9 . Remove a n d clean o r replace the valve.
10. R u b b e r spacer binding in the shift tube. 1 0 . M a k e certain the spacer is p r o p e r l y seated.
Lubricate inside the diameter w i t h silicone
lubricant.
11. Improper f r o n t end alignment. 1 1 . Check a n d adjust t o specifications.
1 2 . S t e e r i n g gear adjusted t o o t i g h t l y . 1 2 . A d j u s t over-center a n d thrust bearing
p r e l o a d t o specifications.
13. Kink in return hose. 1 3 . Replace the hose.
Steering Wheel 1 . L o w o i l level in pump. 1 . A d d p o w e r steering f l u i d as r e q u i r e d .

Surges O r Jerks 2 . Loose pump belt. 2. A d j u s t tension t o specifications.
When Turning 3 . Sticky f l o w control valve. 3 . Replace o r clean the control valve.
W i t h Engine 4 . Insufficient pump p r essu r e. 4 . R e f e r t o " P o w e r S t e e r i n g S y s t e m T e s t " in
Running this section.
Especially D u r i n g
Parking
J9319-64
19-6 STEERING J
Hard Steering 1. L o w tire p r e s s u r e . 1. A d j u s t the tire p r e s s u r e .

E f f o r t In B o t h 2 . Lack o f lubricant in suspension o r ball 2 . Lubricate and relubricate at proper
Directions joints. intervals. Refer to Group O -
Lubrication and Maintenance.
3 . S t e e r i n g gear to column misalignment. 3 . A l i g n the steering column.
4 . Pump belt s l i p p i n g . 4 . T i g h t e n o r replace belt.
5 . L o w f l u i d level in r e s e r v o i r . 5 . Fill to p r o p e r level. Inspect lines and joints
f o r external leakage.
6. H i g h internal leakage (steering g e a r o r 6. Refer to "Pump Pressure Test" in
pump). this section.
7 . Sticky f l o w control valve. 7 . Replace o r clean the valve.
8 . L o w e r coupling f l a n g e rubbing against 8 . Loosen the pinch bolt and assembly
steering gear adjuster p l u g . properly.
9 . S t e e r i n g gear adjusted too tight. 9 . A d j u s t over-center and thrust bearing
p r e l o a d to specifications.
10. Improper f r o n t end alignment. 1 0 . Check and adjust to specifications.
Foaming M i l k y A i r in the f l u i d , and loss o f f l u i d due t o Check f o r leak and correct. Bleed system.
Looking P o w e r internal pump leakage causing Extremely cold temperatures w i l l cause
Steering Fluid, overflow. system aeration should the oil level be l o w .
L o w Level And If oil level is correct and pump still f o a m s ,
Possible L o w remove pump f r o m vehicle and separate
Pressrue r e s e r v o i r f r o m h o u s i n g . Check w e l s h plug
and housing f o r cracks. I f plug is loose o r
housing is cracked, replace housing.
Low Oil Pressure 1 . Check f o r kinks in the hose. 1. Remove the kinks o r replace the hose.
Due T o R e s t r i c t i o n 2. F o r e i g n object stuck in the hose. 2. Remove the foreign object o r replace the
In T h e Hose hose.
Low Oil Pressure 1. Pressure loss in cylinder due to w o r n 1. Disassemble the steering gear as outlined in
Due T o S t e e r i n g piston ring o r scored housing b o r e . the unit r e p a i r manual. Inspect the r i n g and
Gear. R e f e r T o housing b o r e. Replace the affected p a r t s .
" P o w e r Steering 2. Leakage at the valve rings and valve 2 . Disassemble steering gear and replace
S y s t e m Test™ In b o d y t o the w o r m seal. seals.
T h i s Section 3 . Leakage at the valve b o d y o r a loose 3 . Replace the valve.
fitting s p o o l .
4 . D a m a g e d poppet valve. 4. Replace the poppet valve.
Low Oil Prmmurm 1. F l o w control valve stuck o r inoperative. 1. Replace pump.

Due T o S t e e r i n g 2. Pressure plate not f l a t against the cam 2 . Replace pump.
Pump. Refer To ring.
" Pump Pressure 3 . E x t r e m e w e a r o f cam r i n g . 3. Replace pump, flush system.
T e s t " In T h i s 4 . A i r in o i l . 4 . Locate source of leak and correct. Bleed the
Section system.
5. L o w oil level. 5 . Add power steering fluid as required.
6. Pump belt s l i p p i n g . 6. Tighten o r replace belt.
7. D a m a g e d hoses o r steering gear. 7. Replace as necessary.
J9319-14
J STEERING 19 - 7
Chirp Noise in Pump belt s l i p p i n g . T i g h t e n o r replace belt.

Steering Pump
Belt Squeal Pump belt s l i p p i n g . T i g h t e n o r replace belt.

(Particularly
Noticeable A t Full
Wheel Travel And
Standstill
Parking)
G r o w l Noise In Excessive back pressure i n hoses o r Locate restriction a n d correct.

Steering Pump steering gear caused by restriction.
Growl Noise In 1. Scored pressure plates, thrust plate o r 1. Replace pump.

Steering Pump rotor.
(Particularly 2. E x t r e m e w e a r o f cam r i n g . 2 . Replace pump.
Noticeable A t
Standstill
Parking)
G r o a n Noise In 1 . L o w oil level. 1 . A d d p o w e r steering f l u i d as r e q u i r e d .

S t e e r i n g Pump 2 . A i r in the o i l . P o o r pressure hose 2 . T o r q u e the connector. Bleed the system.
connection.
Rattle O r Knock 1 . Pump vanes sticking in rotor slots. 1 . Replace pump, flush system.
Noise In Steering 2 . Pressure hose touching other parts o f 2 . Adjust hose position.
Pump vehicle.
S w i s h Noise In Faulty f l o w control valve. Replace pump.

Steering Pump
W h i n e Noise In Pump shaft bearing scored. Replace pump.

Steering Pump
J9319-13
- 8 STEERING
PUMP LEAKAGE DIAGNOSIS GEAR LEAKAGE DIAGNOSIS

J
W O R N R E P L A C E P U
1. SIDE COVER LEAK - TORQUE 3 . PRESSURE LINE FITTING - TORQUE T H E
2." ^ J ^ g g ® ^ - ^ HOSE FITTING N U T T O 27 N»m (20 F T .
SIDE COVER BOLTS T O 60 N«m
(45 F T . LBS.). REPLACE THE SIDE LBS.). IF LEAKAGE PERSISTS, REPLACE
COVER SEAL IF T H E LEAKAGE THE SEAL.
4 R PERSISTS.
" R?P LACECSNG seal 5 N # m 1 5 5 ft
" h s
' h , F l E A K A G E P E R S , S T S
' 4 . PITMAN SHAFT SEALS - REPLACE T H E
5. REPLACE P U M P . 2 .ADJUSTER PLUG SEAL - REPLACE SEALS.
6. C H E C K O I L L E V E L ; IF L E A K A G E P E R S I S T S WITH T H E LEVEL
T H E ADJUSTER PLUG SEALS.
5 . TOP COVER SEAL - REPLACE THE SEAL.
C O R R E C T A N D C A P TIGHT, REPLACE T H EC A P
J9319-74 J9319-75
STEERING 19 - 9
J
POWER STEERING PUMP
INDEX
page page
Drive Pulley Replacement 11 Pump Replacement 10
Flow Control Valve Fitting O-Ring Seal 12 Reservoir Replacement 12
Power Steering Pump—Initial Operation 13 Service Information 9
Pressure and Return Hose Replacement 9
SERVICE INFORMATION (2) If applicable, remove pressure sensor from pres

The power steering pump internal components are sure hose (Fig. 1, 2).
not serviced or adjusted. If a malfunction or an inter (3) Disconnect pressure and return hose from the
nal fluid leak occurs, the complete unit must be re steering gear. Drain the fluid from pump and reser
placed. A reservoir, cap, and O-ring seal kit are the voir (Fig. 1, 2, 3).
only service components available. (4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2, 3).
PRESSURE AND RETURN HOSE REPLACEMENT
Cap hose open ends and pump/steering gear fit INSTALLATION
tings to prevent entry of foreign material. (1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
WARNING: P O W E R S T E E R I N G F L U I D (AND P U M P
hose while avoiding extreme bends or kinks. T h e
COMPONENTS) AND T H E E X H A U S T S Y S T E M CAN
hose must be kept away from exhaust system
B E E X T R E M E L Y H O T I F T H E ENGINE H A S B E E N
components. Do not distort hose tube ends by bend
R E C E N T L Y O P E R A T I N G . DO NOT S T A R T T H E E N
ing, kinking or over tightening.
GINE W I T H A N Y L O O S E O R D I S C O N N E C T E D
H O S E S . DO NOT A L L O W T H E H O S E S T O T O U C H A (3) If applicable, install and tighten pressure sen
H O T E X H A U S T MANIFOLD O R T H E C A T A L Y T I C sor to 28 N-m (252 in. lbs.) torque (Fig. 1, 2).
CONVERTER. (4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
(5) Tighten fittings at pump and gear to 35 N»m
REMOVAL (25 ft. lbs.) torque.
(1) Remove fasteners from hose retaining brackets (6) Install clamps on return hose on gear, pump
at all locations. and reservoir.
PUMP
REMOTE
RESERVOIR
RADIATOR
RETURN
H O S E
OF ARROW Z
J9219-59
Fig. 1 Power Steering Hose YJ

19 - 10 STEERING
REMOTE
RESERVOIR PRESSURE
HOSE
PRESSURE
SWITCH
R E T U R N HOSE
CLOSURE
PANEL J9219-58
Fig. 2 Power Steering Hose XJ 4 Cylinder

STEERING PUMP REPLACEMENT
PUMP
RESERVOIR REMOVAL
CAUTION: T h e drive belt tension must be released

before removing the pump. If the belt i s not loos
ened, the pump pulley could be damaged.
PRESSURE (1) Remove serpentine drive belt. Refer to Group 7,

HOSE Cooling for additional information.
(2) Place a drain pan under pump.
(3) Remove pressure and return hoses from pump.
Refer to Pressure and Return Hose Replacement in
CLAMP
RETURN
this section.
HOSE (4) Remove 2 rear bracket-to-pump bolts (Fig. 4).
(5) Remove lower nut at adjustment bracket.
(6) Remove adjuster bolt.
(7) Remove upper pivot bolt.
GEAR (8) Tilt pump forward and remove pump and front
bracket assembly from engine bracket.
(9) Remove adjuster collar at lower stud on pump
J9219-57
bracket.
Fig. 3 Power Steering Hose XJ 6 Cylinder (10) Remove pulley from pump. Refer to Drive Pul
ley Replacement in this section (Fig. 5).
(7) After installation, inspect and test for fluid
(11) Remove 3 front bracket-to-pump bolts.
leaks.
j , STEERING t i - 11
Fig. 4 Pump Mounting (4.0L 1-6)

INSTALLATION (2) Remove the drive pulley with Puller C-4333 (J-
(1) Install 3 front bracket-to-pump bolts. Tighten 25034-B) (Fig. 5).
(2) Install pulley on pump. Refer to Drive Pulley
Replacement in this section (Fig. 6).
(3) Install adjuster collar on adjuster bracket stud
(Fig. 4).
(4) Tilt pump forward and install pump onto en
gine bracket.
(5) Install upper pivot bolt.
(6) Install lower adjuster bolt.
(7) Install lower adjuster stud nut.
(8) Install 2 rear engine bracket to pump bolts.
Tighten to 28 N-m (21 ft. lbs.) torque.
(9) Install the serpentine drive belt. Refer to Group
7, Cooling for additional information.
(10) Install the pressure and return hoses to pump.
Refer to Pressure and Return Hose Replacement in
this section. Fig. 5 Remove Drive Pulley (Typical)
(11) Add power steering fluid. Refer to Power Do not hammer on any part of drive pulley,
Steering Pump Initial Operation in this section. damage will occur to the pump and pulley.
DRIVE PULLEY REPLACEMENT INSTALLATION
(1) Install the pulley with Installer C-4063 (J-
REMOVAL
25033-B) (Fig. 6). Do not use the tool adapters.
(1) Remove power steering pump. Refer to Pump
Replacement in this section.
1i - 12 STEERING J
Fig. 6 Install Drive Pulley (Typical) Fig. 8 Remove Reservoir Clips (Typical)
(2) Be sure tool and pulley remain aligned and CAP
NOT cocked with the pump shaft.
(3) Press the pulley on flush with end of pump
shaft (Fig. 7).
(4) Install power steering pump. Refer to Pump Re
placement in this section.
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.). Be care
ful that pulley does not contact mounting bolts.
PULLEY PUMP
PUMP
BODY J9219-28
Fig. 9 Remove Reservoir (Typical)

INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
Fig. 7 Pump Shaft Location (3) Install reservoir onto housing.
(4) Slide and tap in reservoir retainer clips until
RESERVOIR REPLACEMENT
tab locks to housing.
REMOVAL (5) Install power steering pump. Refer to Pump Re
(1) Remove power steering pump. Refer to Pump placement in this section.
Replacement in this section.
(2) Clean exterior of pump with solvent. FLOW CONTROL VALVE FITTING 0-RING SEAL
(3) Clamp the pump body in a soft jaw vice.

REMOVAL
(4) Pry up tab and slide the retaining clip off (Fig.
(1) Clean area around fitting to prevent dirt from
8).
entering pump. Remove pressure hose from pump fit
(5) Remove fluid reservoir from pump body. Re
ting.
move and discard O-ring seal (Fig. 9).
4 STEERING 19 - 13
(2) Remove fitting from pump housing (Fig. 10). (3) Install flow control valve in pump housing and
Prevent flow control valve and spring from slid tighten to 75 N-m (55 ft. lbs.) torque.
ing out of housing bore. (4) Install pressure hose to valve.
POWER STEERING PUMP—INITIAL OPERATION

CAUTION: T h e fluid level should be checked with
engine off to prevent injury from moving compo
nents. Use only Mopar Power Steering Fluid. Do not
use automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.

The dipstick should indicate FULL COLD when the
fluid is at normal temperature 21°C to 27°C (70°F to
80°F).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
TIGHTEN T O 7 5 N-m (55 FT. LBS) J9319-17 Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce
Fig. 10 Flow Control Valve Fitting dure until the fluid level remains constant after run
ning the engine.
(3) Remove and discard O-ring seal.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
INSTALLATION
wheel right and left, lightly contacting the wheel
(1) If necessary, clean and install flow control stops.
valve and spring in pump housing bore. Be sure the (6) Add power steering fluid if necessary.
hex nut end of the valve is facing in toward (7) Lower the vehicle and turn the steering wheel
pump. slowly from lock to lock.
(2) Install O-ring seal onto fitting (Fig. 10). (8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi
cle to stand a few minutes and repeat the above pro
cedure.
19 - 14 STEERING J
STEERING L I N K A G E - XJ
INDEX
page page
Drag Link 14 Steering Dampener 15
Pitman Arm 15 Tie Rod . . . . . ........... 14
Service Information 14
SERVICE INFORMATION TIE ROD

The steering linkage consists of a pitman arm,
drag link, tie rod, and steering dampener. Adjust REMOVAL
ment sleeves are used on the tie rod and drag link (1) Remove the cotter pins and nuts at the tie rod
for toe and steering wheel alignment. ball studs and drag link (Fig. 2).
Refer to Group 2, Front Suspension and Axle for (2) Loosen the ball studs with a puller tool to re
additional information. move the tie rod.
The tie-rod end ball stud seals should be inspected (3) If necessary, loosen the end clamp bolts and re
during all oil changes. move the tie rod ends from the tube.
A damaged ball stud seal requires removal of the
INSTALLATION
ieal. Inspect the tie-rod end ball stud at the throat
(1) If necessary, install the tie rod ends in the tube
opening. Check for lubricant loss, contamination, ball
(Fig. 2). Position the tie rod clamp as shown (Fig. 3)
stud wear or corrosion. If these conditions exist, re
and tighten to 27 N-m (20 ft. lbs.) torque.
place the tie-rod. A replacement seal can be installed
(2) Install the tie rod on the drag link and steering
if lubricant is in good condition. Otherwise, a com
knuckle. Install the retaining nuts.
plete replacement ball stud end should be installed.
(3) Tighten the ball stud nut on the steering
Lubricate the tie-rod end with MOPAR® Multi-Mile
knuckle to 47 N-m (35 ft. lbs.) torque. Tighten the
age Lubricant, or equivalent product.
ball stud nut to drag link to 75 N-m (55 ft. lbs.)
Use a Puller tool for tie rod removal. Failure
torque. Install new cotter pins.
to use this tool could damage the ball stud and
seal (Fig. 1).
DRAG LINK
REMOVAL
The drag link ball stud cannot be disassem
bled for service.
(1) Remove the steering dampener ball stud from
the drag link with a puller tool.
(2) Remove the drag link from the steering
knuckle with a puller tool. Remove the same for tie
rod and pitman arm.
(3) If necessary, loosen the end clamp bolts and re
move the tie rod end from the link.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod end. Position clamp bolts as shown (Fig. 3).
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the nut that attach the drag link to the
steering knuckle. Do the same for the tie rod and pit
man arm.
J9202-48 (3) Tighten the nut at the steering knuckle to 47
N-m (35 ft. lbs.) torque. Tighten the pitman and tie
Fig. 1 Ball Stud Removal rod ball stud nuts to 75 N-m (55 ft. lbs.) torque. In
stall new cotter pins.
J STEERING 19 - 15
-..V^VSHER
TIE ROD J9319-1

TIE ROD
(3) Remove the cotter pin and nut from the ball
CLAMP stud at the drag link (Fig. 2).
the drag link with a puller tool.
INSTALLATION
(1) Install the steering dampener to the axle
bracket and drag link.
(2) Install the steering dampener bolt in the axle
bracket. Tighten the nut to 75 N-m (55 ft. lbs.)
torque.
(3) Install the ball stud nut at the drag link.
Tighten the nut to 75 N-m (55 ft. lbs.) torque. Install
a new cotter pin.
PITMAN ARM
Fig. 3 Tie Rod/Drag Link damp Bolt
(4) Install the steering dampener onto the drag REMOVAL
link. Tighten the nut to 47 N-m (35 ft. lbs.) torque. (1) Remove the cotter pin and nut from the drag
Install a new cotter pin. link at the pitman arm.
(2) Remove the drag link ball stud from the pit
STEERING DAMPENER man arm with a puller.
(3) Remove the nut and washer from the steering
REMOVAL gear shaft. Mark the pitman shaft and pitman arm
( 1 ) Place the front wheels in a straight-ahead posi for installation reference. Remove the pitman arm
tion. from steering gear with Puller 7998 or C-4150 (Fig.
(2) Remove the steering dampener retaining nut 4).
and bolt from the axle bracket (Fig. 2).
19 - 16 STEERING J
INSTALLATION
(1) Align and install the pitman arm on steering
gear shaft.
(2) Install the washer and nut on the shaft.
Tighten the nut to 251 N*m (185 ft. lbs.) torque.
(3) Install drag link ball stud to pitman arm (Fig.
4). Install and tighten nut to 74 N*m (55 ft. lbs.)
J9119-24
Fig. 4 Pitman Arm Removal

J STEERING 19 - 17
STEERING LINKAGE—YJ
INDEX
page page
Drag Link . . 17
17 Steering Dampener 18
Pitman Arm . . 19
19 Tie Rod . . . . . . . . . . 17
Service Information . . . . . . . . . . . . . . . . . . . . . . . 17
SERVICE INFORMATION TIE ROD

The steering linkage consists of a pitman arm,
drag link, tie rod, and steering dampener. Adjust REMOVAL
(1) Remove the cotter pins and nuts at the steering
ment sleeves are used on the tie rod and drag link
knuckles and drag link (Fig. 2). Remove the steering
for toe and steering wheel alignment. dampener from the tie rod.
Refer to Group 2, Front Suspension and Axle for (2) Loosen the ball studs with a puller tool to re
additional information. move the tie rod.
The tie-rod end ball stud seals should be inspected (3) If necessary, loosen the end clamp bolts and re
during all oil changes. move the tie rod end from the tube.
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat INSTALLATION
opening. Check for lubricant loss, contamination, ball (1) If necessary, install the tie rod end in the tube
stud wear or corrosion. If these conditions exist, re (Fig. 2). Position the tie rod clamp as shown (Fig. 3).
Tighten the ball-stud end clamp bolts to 49 N-m (36
place the tie-rod. A replacement seal can be installed
ft. lbs.) torque.
if lubricant is in good condition. Otherwise, a com
(2) Install the tie rod on the drag link and steering
plete replacement ball stud end should be installed. knuckles. Install the retaining nuts. Install the steer
Lubricate the tie-rod end with MOPAR® Multi-Mile ing dampener to the tie rod.
age Lubricant, or equivalent product. (3) Tighten the ball stud nut on the steering
Use a Puller tool for tie rod removal. Failure knuckle to 47 N-m (35 ft. lbs.) torque. Tighten the
to use this tool could damage the ball stud and ball stud nut to drag link to 75 N-m (55 ft. lbs.)
seal (Fig. 1). torque. Tighten the steering dampener nut to 74 N-m
(55 ft. lbs.) torque. Install new cotter pins.
DRAG LINK
REMOVAL
(1) Remove the cotter pins and nuts at the tie rod
and pitman arm (Fig. 2).
(2) Remove the drag link from the tie rod and pit
man arm with a puller tool.
(4) If necessary, loosen the end clamp bolts and re
move the tie rod ends from the tube.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod ends. Position clamp bolts as shown (Fig. 3).
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the drag link to tie rod and pitman arm.
(3) Tighten the nut at the pitman arm to 74 N-m
(55 ft. lbs.) torque. Tighten the tie rod ball stud nut
to 75 N-m (55 ft. lbs.) torque. Install new cotter pins.
J9202-48
Fig. 1 Ball Stud Removal

IS - 18 STEERING J
NUT BOLT
PITMAN
ARM
NUT
BALL
STUD
TIE ROD
END
CLAMP
DRAG
LINK END T I E ROD E N D J9202-2
CLAMP

TIE ROD (2) Install the steering dampener bolt in the axle
CLAMP bracket. Tighten the nut to 74 N*m (55 ft. lbs.)
torque.
(3) Install the ball stud nut at the tie rod. Tighten
the nut to 74 Nnn (55 ft. lbs.) torque. Install a new
cotter pin.
DRAG LINK
CLAMPS J9302-10
Fig. 3 Tie Rod/Drag Link Clamp Bolt

STEERING DAMPENER
REMOVAL
(1) Place the front wheels in a straight-ahead posi
tion.
(2) Remove the steering dampener retaining nut
and bolt from the axle bracket (Fig. 2).
(3) Remove the cotter pin and nut from the ball
stud at the tie rod (Fig. 2).
the tie rod with a puller tool.
INSTALLATION
(1) Install the steering dampener to the axle
bracket and tie rod.
STEERING 19 - 19
PITMAN ARM
REMOVAL
(1) Remove the cotter pin and nut from the drag
link at the pitman arm.
(2) Remove the drag link ball stud from the pit
man arm with a puller.
(3) Remove the nut and washer from the steering
gear shaft. Mark the pitman shaft and pitman arm
for installation reference. Remove the pitman arm
from steering gear with Puller 7998 or C-4150 (Fig.
4).
INSTALLATION
(1) Align and install the pitman arm on steering
gear shaft.
(2) Install the washer and nut on the shaft.
Tighten the nut to 251 N-m (185 ft. lbs.) torque. SPECIAL TOOL
7998
(3) Install drag link ball stud to pitman arm (Fig. OR
4). Install and tighten nut to 74 N-m (55 ft. lbs.) J9119-24
J-6632-01
Fig. 4 Pitman Arm Removal
RECIRCULATING BALL POWER STEERING GEAR
INDEX
page page
Adjuster Plug Assembly Replacement 27 Pitman Shaft Seals—In Car Replacement 21
Check Valve Replacement 33 Rack Piston and Worm Shaft Replacement . . . . . 30
Gear Disassembly Information 24 Service Information 19
Housing End Plug 26 Steering Gear Adjustments 22
Intermediate (Coupler) Shaft . 21 Steering Gear Replacement 21
Pitman Shaft and Side Cover Replacement . . . . . 26
Valve Replacement 28
Pitman Shaft Seals and Bearing Replacement . . . 32
SERVICE INFORMATION Discard all O-ring seals during disassembly,

A recirculating-ball steering gear is used with the they are not re-usable.
Safety goggles should be worn at all times
power (assisted) steering system (Fig. 1). The power
when involved with power steering gear or
steering gear can be adjusted and internally serviced.
pump service.
STEERING 19 - 21
J
PITMAN SHAFT SEALS-IN CAR REPLACEMENT
REMOVAL
(1) Remove pitman arm from gear. Refer to Pit
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 2).
RETAINING RING
BACKUP WASHER
D O U B L E - U P SEAL
BACKUP WASHER
SINGLE-LIP SEAL
N E E D L E BEARING
Fig. 3 Pitman Shaft Seal Installation

(9) Add power steering fluid. Refer to Power Steer
ing Initial Operation.
INTERMEDIATE (COUPLING) SHAFT
J8919-39
REMOVAL
(1) Place the front wheels in the straight ahead po
sition.
Fig. 2 Pitman Shaft Seals (2) Remove the shaft pinch bolt at the steering
CAUTION: Use care not to score the housing bore gear and column (Fig. 4, 5). Unbolt steering gear
when prying out seals and washers. from frame rail to remove shaft. Refer to Steering
Gear Replacement in this section.
(4) Remove backup washer and double lip seal
with screwdriver. INSTALLATION
• Start the engine and turn the steering wheel fully (1) Align the intermediate (coupler) shaft to the
to the LEFT to force out the seals and washers. steering gear and column.
• Stop the engine (2) Position the steering gear on the frame. Refer
(5) Remove backup washer and single lip seal with to Steering Gear Replacement in this section.
screwdriver. (3) Install and tighten the pinch bolts to 34 N-m
(6) Inspect the housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for
roughness and pitting. If pitted replace shaft.
STEERING GEAR REPLACEMENT
(1) Install single lip seal with Installer or a suit (1) Place the front wheels in the straight ahead po
able size deep socket (Fig. 3).
sition with the steering wheel centered.
(2) Coat the double lip seal and washer with
(2) Disconnect and cap the fluid hoses from steer
grease.
ing gear. Refer to Pressure and Return Hose Replace
(3) Install the backup washer.
(4) Install the double lip seal. ment in this Group.
(5) Install the backup washer. (3) Remove the column coupler shaft from the
(6) Install the retainer ring with snap ring pliers. gear. Refer to the removal procedures in this section.
(7) Center the steering gear. (4) Remove pitman arm from gear. Refer to Pit
(8) Install the pitman arm. Refer to Pitman Arm man Arm Removal in the Steering Linkage section.
Installation in Steering Linkage.
19 - 22 STEERING J
FRAME WASHER SCREW
J9119-48 GEAR J9219-46
Fig. 4 Couplet Shaft- XJ Fig. 6 Steering Gear Mounting—XJ
Fig. S 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 (4) Connect fluid hoses to steering gear. Refer to
gear. Refer to Column Coupler installation in this Pressure and Return Hose Replacement in this
section. Group.
(2) Position the steering gear (and bracket) on the
frame rail and install the bolts. STEERING GEAR ADJUSTMENTS
• X J - Tighten the bolts to 95 N-m (70 ft. lbs.)
torque SERVICE INFORMATION
• YJ— Tighten the bolts to 105 N-m (78 ft. lbs.) Adjusting the steering gear in the vehicle is NOT
torque recommended. Remove the gear from the vehicle and
(3) Align and install the pitman arm. Refer to Pit mount in a vise. Drain the power steering fluid and
man Arm Installation in the Steering Linkage sec make the following adjustments in this order:
tion. • FIRST - worm thrust bearing preload
a STEERING 19 - 23
• SECOND - over-center preload adjustment (4) Measure back (counterclockwise) 13 mm (0.50)

and mark housing (Fig. 10).
WORM THRUST BEARING PRELOAD
ADJUSTMENT
(1) Remove adjuster plug lockiiut (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. 11).
Fig. 8 Loosening the Adjuster Plug Locknut FIRST
(2) Turn the adjuster in with Spanner Wrench MARK
C-4381 (J7624). Tighten the plug and thrust bearing

in the housing until firmly bottomed in housing.
(3) Place an index mark on the housing even with
one of the holes in adjuster plug (Fig. 9).
J9219-30
Fig. 11 Aligning To The Second Mark

(6) Install and tighten locknut to 109 N*m (80 ft.
lbs.) torque. Be sure adjustment cap does not turn
J8919-58
while tightening the locknut.
Fig. 9 Alignment Marking On Housing OVER CENTER ADJUSTMENT

(1) Rotate the stub shaft from stop to stop and
count the number of turns.
19 - 24 STEERING J
(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

GEAR DISASSEMBLY INFORMATION
Fig. 12 Steering Gear Centered CAUTION: Cleanliness i s extremely important when
(3) Turn the pitman shaft adjuster screw back repairing a power steering gear. Keep the bench,
(COUNTERCLOCKWISE) until extended, then turn tools and components clean at all times. T h o r
back in (CLOCKWISE) one full turn. oughly clean the exterior of the gear with cleaning
(4) Place the torque wrench in the vertical position solvent before disassembly. Drain as much of the
on the stub shaft. Rotate the wrench 45 degrees each fluid as possible. U s e protective vise jaws at all
side of the center and record the highest rotational times when clamping components. During assem
torque on center (Fig. 13). bly, lubricate all components with power steering
(5) Turn the adjuster in until torque to turn stub fluid except where noted (Fig. 14).
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more than
reading in Step 4.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 49 N*m (36 ft. lbs.).
1 - HOUSING, STEERING GEAR 2 5 - B E A R I N G A S S Y . , N E E D L E (PlTAAAN S H A F T )
2 - RACE, T H R U S T B E A R I N G (WORM) 2 6 - S E A L , PlTAAAN S H A F T (SINGLE LIP)
3 - B E A R I N G A S S Y . , ROLLER T H R U S T (WORM) 2 7 - W A S H E R , S E A L B A C K - U P (PlTAAAN S H A F T )
4 - RACE, T H R U S T B E A R I N G (WORM) 28 - S E A L , PlTAAAN S H A F T ( D O U B L E LIP)
5 - WORM, STEERING 2 9 - W A S H E R , S E A L B A C K - U P (PlTAAAN S H A F T )
6 - S E A L "O" R I N G ( S T U B S H A F T ) 30 - R I N G , R E T A I N I N G (PlTAAAN S H A F T SEAL)
7 - SHAFT, STUB 31 - W A S H E R , PlTAAAN S H A F T LOCK
8 - S P O O L , VALVE 3 2 - N U T , PlTAAAN S H A F T
9 - S E A L , "O" R I N G (SPOOL) 3 3 - N U T , RACK P I S T O N
1 0 - B O D Y , VALVE 34 - B A L L
11 - R I N G , VALVE B O D Y (3)
® 1 2 - S E A L , "O" R I N G (VALVE BODY) (3)
3 5 - G U I D E , B A L L R E T U R N (2)
3 6 - CLAMP, BALL R E T U R N G U I D E
13 - R E T A I N E R , B E A R I N G ( A D J U S T E R ) 3 7 - SCREW A S S Y . , LOCKWASHER & (2)
14 - SPACER, T H R U S T B E A R I N G 38 - P L U G , RACK P I S T O N
1 5 - RACE, U P P E R T H R U S T B E A R I N G (SAAALL) 3 9 - S E A L , "O" R I N G (RACK P I S T O N )
1 6 - BEARING, UPPER T H R U S T 4 0 - R I N G , RACK P I S T O N
17 - RACE, U P P E R T H R U S T B E A R I N G (LARGE) 41 - S E A L , "O" R I N G ( H O U S I N G E N D PLUG)
18 - S E A L , "O" R I N G (ADJUSTER) 4 2 - PLUG, HOUSING END
19- PLUG, ADJUSTER 4 3 - R I N G , R E T A I N I N G ( H O U S I N G E N D PLUG)
2 0 - BEARING, NEEDLE 44 - G E A R A S S Y . , PlTAAAN S H A F T
21 - S E A L , S T U B S H A F T 45 - SEAL A S S Y . , G A S K E T m
2 2 - SEAL, S T U B S H A F T DUST 4 6 - COVER A S S Y . , H O U S I N G SIDE m
2 3 - RING, RETAINING 4 7 - BOLT, H E X . H E A D (SIDE COVER) (4) EE
24 - N U T , A D J U S T E R P L U G LOCK 48 - N U T , L A S H A D J U S T E R
J9219-64
Fig. 14 Power Steering Gear CO
ro
CJl
19-26 STEERING J
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.
Power Steering Gear Replacement in this section. #
(5) Install side cover bolts and tighten to 60 N m
(2) Remove pitman arm from steering gear. Refer (44 ft. lbs.).
to Pitman Arm Removal in the Steering Linkage sec (6) Adjust pitman shaft, refer to Over-Center Ad
tion. justment.
(3) Rotate stub shaft back and forth to drain power
steering fluid. INSTALL
(1) Install steering gear. Refer to Power Steering
DISASSEMBLE Gear Replacement in this section.
• Clean exposed end of pitman shaft and housing. (2) Install pitman arm onto steering gear. Refer to
• Clean pitman shaft spline with a wire brush. Steering Linkage in this Group.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear. HOUSING END PLUG
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as REMOVE
an assembly. (1) Remove steering gear from vehicle. Refer to
(4) Remove pitman shaft from the side cover (Fig. Power Steering Gear Replacement in this section.
15). (2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this Group.
SIDE COVER BOLTS (3) Rotate stub shaft back and forth to drain power
TORQUE T O 60 N-m
(40 FT. LBS.) steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid
PRELOAD
ADJUSTER N U T
(1) Rotate retaining ring until one end is under
the hole in the housing. Unseat and force ring from
SIDE COVER groove (Fig. 16).
GASKET SEAL
PlTAAAN SHAFT
GEAR
RETAINING
RING
HOUSING ASSEMBLY
J9319-31
Fig. 15 Side Cover and Pitman Shaft J8919-31
ASSEMBLE Fig. 16 End Plug Retaining Ring

(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover. (2) Rotate stub shaft slowly COUNTER-CLOCK
(2) Install preload adjuster nut. Do not tighten WISE to remove end plug out from housing (Fig. 17).
nut until after pitman shaft adjustment has been
made.
CAUTION: Do not turn stub shaft any farther than (2) Install pitman arm onto steering gear. Refer to
necessary. The recirculating balls will drop out of Steering Linkage in this Group.
the rack piston circuit and fall inside the rack pis
ton chamber. ADJUSTER PLUG ASSEMBLY REPLACEMENT
(3) Remove O-ring seal (Fig. 17). REMOVE

(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span
ner Wrench C-4381 (J7624) (Fig. 19).
SPECIAL TOOL
C-4381 OR J-7624
HOUSING END PLUG

O-RING SEAL
HOUSING END PLUG
RETAINING RING J9319-30
Fig. 17 End Plug Components

ASSEMBLE
• Lubricate O-ring seal with power steering fluid
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1
Fig. 19 Remove/Install Adjustment Plug
inch) from access hole (Fig. 18).
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 20).
BEARING RETAINER
Fig. 18 Installing The Retaining Ring

INSTALL Fig. 20 Remove Retainer
19-28 STEERING J
(4) Remove bearing spacer, races and thrust bear (1) Install needle bearing into adjuster plug with
ing (Fig. 21). an appropriate tool.
(2) Install lip seal and dust seal into adjuster plug
LARGE
RETAINING with an appropriate tool.
THRUST
S N A P RING
f
STUB SHAFT
WASHER (3) Install retainer snap ring.
D U S T SEAL (4) Install O-ring seal to adjuster plug.
SMALL
T H R U S T WASHER
(5) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(6) Install thrust washer bearing retainer to ad
juster plug (Fig. 23).
PUNCH
NEEDLE
BEARING
NEEDLE
BEARING SEAL
ADJUSTMENT
RETAINER
CAP
ADJUSTER
Fig. 21 Adjustment Plug (Cap) Components

(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
J9219-10
with an appropriate tool (Fig. 2 2 ) .
Fig. 23 Install Retainer
CAUTION: When installing adjuster plug, care
should be taken NOT to cut the seals.
(7) Install adjuster plug into housing with Spanner

Wrench C-4381 (J7624).
(8) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(9) Install adjuster plug lock nut, and using a
NEEDLE punch (drift) in a notch, tighten securely (Fig. 24).
BEARING
REMOVAL
Hold adjuster plug to maintain alignment of the
TOOL marks.
(10) Adjust pitman shaft. Refer to Over-Center Ad
justment.
INSTALL
VALVE REPLACEMENT
J8919-43
REMOVE
Fig. 22 Needle Bearing Removal
(1) Remove steering gear from vehicle. Refer ,to
ASSEMBLE Power Steering Gear Replacement in this section.
CAUTION: Needle bearing must be installed with DISASSEMBLE

identification on bearing facing tool to prevent dam (1) Remove adjuster plug, refer to Adjuster Plug
age to bearing. Assembly Replacement.
STEERING 19 - 29
J9319-36
Fig. 26 Remove and Install Stub Shaft

Fig. 24 Tighten Lock Nut
(2) Remove stub shaft and valve assembly (Fig.
GEAR, MAKE SURE ANGLE OF Fig. 27 Remove and Install Spool

THRUST RACES ARE A S S H O W N . J9319-32
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
Fig. 25 Bearing, Worm and Valve Assembly
(2) Lubricate valve spool and O-ring seal with
(3) Remove stub shaft from valve assembly, if nec power steering fluid.
essary. (3) Install valve spool to valve body by pushing
• Tap stub shaft lightly on a block of wood to loosen and rotating. Hole in valve spool for stub pin must
shaft cap be accessible from opposite end of valve body.
• Pull cap and valve body and disengage stub shaft (4) Assemble stub shaft to valve spool, if necessary
pin from hole in valve body (Fig. 26). and insert pin (Fig. 29).
(4) Remove valve assembly if necessary. • Notch in stub shaft cap MUST fully engage valve
• Remove valve spool by pulling and rotating from body pin and seat against valve body shoulder.
valve body (Fig. 27). (5) Install O-ring seals and teflon rings to valve
• Remove valve spool O-ring seal body.
• Remove valve body teflon rings and O-ring seals (6) Lubricate O-ring seals and teflon rings with
(Fig. 28). power steering fluid.
19 - 30 STEERING
RACK PISTON AND WORM SHAFT REPLACEMENT

REMOVE
DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 30).
EXTENSION E N D PLUG
Fig. 28 Remove and Install Valve Seals
Fig. 30 Remove and Install Rack Piston End Plug

(5) Insert Arbor C-4175 (J-21552) into bore of rack
piston (Fig. 31). Hold tool tightly against worm shaft
while turning the stub shaft COUNTERCLOCK
WISE.
• The rack piston will be forced onto the tool and
hold the rack piston balls in place.
Fig. 29 Stub Shaft Installation (6) Remove the rack piston, rack balls, and tool to
gether from housing.
(7) Install stub shaft and valve assembly to worm
(7) Remove valve. Refer to Valve Replacement in
shaft, fitting on worm shaft to slot in the valve as
this section.
sembly.
(8) Remove worm shaft.
(8) Adjust Thrust Bearing Preload Adjustment and
(9) Remove thrust bearing and races.
Over-Center Adjustment. Refer to Steering Gear Ad
(10) Remove tool from rack piston.
justments in this section.
(11) Remove rack piston balls.
INSTALL (12) Remove screws, clamp and ball guide.
(1) Install steering gear. Refer to Power Steering (13) Remove teflon ring and O-ring seal (Fig. 32).
STEERING 19 - 31
INSTALL BALLS IN THIS HOLE

WHILE SLOWLY ROTATING
W O R M COUNTERCLOCKWISE
J9319-39
Fig. 31 Remove and Install Rack Piston Fig. 33 Installing Balls in 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 silver
balls. THE BLACK AND SILVER BALLS MUST
BE INSTALLED ALTERNATELY INTO THE
RACK PISTON AND BALL GUIDE. This proce
dure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning wormshaft COUN
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 34).
(5) Install guide onto rack piston and return with
GUIDE
J9219-12
Fig. 32 Remove and Install Seal on Rack Piston

CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
(2) Check for scores, nicks or burrs on the rack pis
ton finished surface. Slight wear is normal on the
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston and
BALLS J9319-40
align worm shaft spiral groove with rack piston ball
guide hole (Fig. 33).
Fig. 34 Balls in the Return Guide
WARNING: MAKE S U R E A L L RACK P I S T O N B A L L S clamp and screws. Tighten screws to 58 N»m (43 in.
A R E R E I N S T A L L E D IN T H E RACK P I S T O N . IM lbs.) torque.
P R O P E R I N S T A L L A T I O N MAY R E S U L T IN P E R (6) Insert Arbor C-4175 (J-21552) into bore of rack
SONAL INJURY. piston. Hold tool tightly against worm shaft while
19 - 3 2 STEERING J
turning 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. 35). (1) Remove steering gear from vehicle. Refer to
W O R M SHAFT THRUST RACES
DISASSEMBLE
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 36).
RETAINING RING
BACKUP WASHER
D O U B L E - U P SEAL
BACKUP WASHER
SINGLE-LIP SEAL
N E E D L E BEARING
MAKE SURE ANGLE OF T H R U S T

RACES ARE A S S H O W N ^ ^ ,
J9319-41
Fig. 35 Worm Shaft and Bearing

(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals. J8919-39
• Hold Arbor tightly against worm shaft and turn
stub shaft CLOCKWISE until rack piston is seated
Fig. 36 Pitman Shaft Seals
on worm shaft.
CAUTION: Use care not to score the housing bore
WARNING: M A K E S U R E A L L R A C K P I S T O N B A L L S when prying out seals and washers.
A R E R E I N S T A L L E D IN T H E RACK P I S T O N . IM
P R O P E R I N S T A L L A T I O N MAY R E S U L T IN P E R (4) Remove backup washer and double lip seal
SONAL INJURY. with screwdriver.
(5) Remove backup washer and single lip seal with
(11) Install rack piston plug and tighten to 150 screwdriver.
N*m (111 ft. lbs.) torque. (6) Inspect the housing for burrs and remove if
(12) Install housing end plug. Refer to Housing necessary.
End Plug Replacement in this section. (7) Remove needle bearing from side cover area of
(13) Install pitman shaft and side cover. Refer to housing (Fig. 37).
Side Cover and Pitman Shaft Replacement in this
ASSEMBLE
section.
(1) Install needle bearing into housing (Fig. 38).
(14) Adjust steering gear. Refer to Steering Gear
(2) Install single lip seal with Installer or a suit
Adjustments in this section. able size socket (Fig. 39).
(3) Coat the double lip seal and washer with
INSTALL
grease.
(5) Install the double lip seal.
J STEERING 19-33
REMOVER SIDE COVER

AREA
SPECIAL TOOL
7616 OR
J-21553
J9319-42 J9119-29
Fig. 37 Needle Bearing Removal Fig. 39 Pitman Shaft Seal Installation

(8) Install the pitman shaft and side cover. Refer
to Side Cover and Pitman Shaft Replacement in this
section.
SPECIAL TOOL
8015 OR J-8092 INSTALL
SPECIAL TOOL
7614 OR J-21551 CHECK VALVE REPLACEMENT
REMOVE
DISASSEMBLE
C A U T I O N : U s e c a r e not to d a m a g e t h e t h r e a d s of
t h e h o u s i n g when prying out c h e c k valve.
(1) Remove valve by prying from housing with a

small screwdriver.
J9f 19-28
ASSEMBLE
Fig. 38 Pitman Shaft Bearing Installation (1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 mm (4 inches)
(7) Install the retainer ring with snap ring pliers. long.
INSTALL
19 - 34 STEERING J
POWER STEERING GEAR SPECIFICATIONS
Steering G e a r T y p e . Recirculating ball with S t e e r i n g G e a r Adjustments:

hydraulic assist. W o r m s h a f t Bearing Preload Torque . . . . . 0 . 4 5 - 1 . 1 3 N-m
(4 to 10 in-lbs)
Ratio Code (Top o f G e a r )
BH, N Z 14:1 Pitman S h a f t Overcenter D r a g Torque:
BF,XS ....... 13-16:1 N e w Gear
AL 12.7:1 (less than 4 0 0 m i l e s / 6 4 0 km) . . . . . 0.45-0.90 N m
(4 to 8 in-lbs) in addition to wormshaft
Steering G e a r Hydraulic F l u i d U s e M o p a r Power bearing preload but not to exceed
Steering F l u i d , o r equivalent. combined total of 2 N-m (18 in-lbs).
Steering G e a r Lubricants Lubricate pitman shaft Used Gear

seals, bearings races, and rack (over 4 0 0 m i l e s / 6 4 0 km) . . . . 0 . 5 - 0 . 6 N-m (4 to 5 in-lbs)
piston recirculating balls with in addition to wormshaft bearing
petroleum jelly. Lubricate all other preload but not to exeed
parts w i t h p o w e r steering f l u i d . combined total of 2 N-m (18 in-lbs).
Caution: G e a r s must be adjusted exactly as outlined in

Steering G e a r Adjustments-On Bench. Failure to
adhere to the recommended procedures may result
in gear damage o r improper steering response.
J9319-44
STEERING 19 - 35
MANUAL STEERING GEAR
INDEX
page page
Diagnosis 36 Gear Disassembly 37
Gear Adjustments in Vehicle 37 Information 35
Gear Adjustments on Bench 42 Intermediate (Coupler) Shaft 43
Gear Assembly 41 Pitman Shaft Seal Replacement 37
Gear Cleaning and Inspection 38 Steering Gear Replacement 43
INFORMATION
The manual steering gear installed on Jeep vehi
cles (Fig. 1) has a variable steering ratio.
TOP VIEW SECTION V I E W
1. Ball N u t 10. Jam N u t

2. W o r m Bearing 11. Adjuster Screw
3. Seal 12. Side Cover Bolt
4. Wormshaft 13. Side Cover
5. Balls and Guides 14. Pitman Shaft Bearing
6. Adjuster Plug 15. Pitman Shaft Seal
7. Adjuster Nut 16. Pitman Shaft
8. W o r m Bearing (Lower) 17. Spring W a s h e r
9. Pitman Shaft Sector 18. Nut
J9219-33
Fig. 1 Manual Steering Gear

19-36 STEERING J
DIAGNOSIS
MANUAL STEERING SYSTEM DIAGNOSIS
R a t t l e O r Chuckle 1 . Insufficient or improper lubricant in the 1 . Add lubricant as required.

In T h e S t e e r i n g steering gear.
Gear 2 . Pitman arm loose on the shaft or the 2. Tighten to specified torque.
steering gear mounting bolts loose.
3 . Loose or worn steering shaft bearing. 3. Replace the steering shaft bearing.
4 . Excesisve over-center lash or worm thrust 4. Adjust the steering gear to specified
bearings adjusted too loose. On turns a preloads.
slight rattle may occur, due to the
Increased lash between ball nut and
pitman shaft as gear moves off the
center of ''high p o i n t " position. This is
normal and lash must not be reduced to
eliminate this slight rattle.
Pear Return O f 1 . Steering column misaligned. 1. Align the column.

The Steering 2 . Insufficient o r improper lubricant in the 2 . Lubricate as specified.
Wheel steering gear or front suspension.
3 . Steering gear adjusted too tight. 3. Adjust over-center and thrust bearing
preload to specifications.
4 . Front wheel alignment incorrect (Caster). 4. Adjust to specifications.
Excessive P l a y O r 1 . Front wheel bearings loosely adjusted. 1. Adjust bearings or replace with new parts as
Looseness i n T h e necessary.
Steering System 2 . Steering system out o f alignment. 2. Align caster, camber, and toe-in.
3 . Worn upper ball joints. 3. Check and replace ball joints if necessary.
4. Steering wheel loose on the shaft, loose 4. Tighten to specification, replace if worn or
pitman arm, tie rods, steering arms or damaged.
steering linkage ball nuts.
5 . Tires badly worn, edge of tires rounded 5 . Install new tires, and check alignment.
off.
6 . Excessive over-center lash. 6. Adjust over-center preload to specifications.
7. Worm thrust bearings loosely adjusted. 7. Adjust the worm thrust bearing preload to
specifications.
Hard S t e e r i n g - 1. Low or uneven tire pressure. 1. Inflate to specified pressures.

Excessive I f f a r t 2. Insufficient or improper lubricant in the 2. Lubricate as specified. Relubricate at
Required At The steering gear o r front suspension. specified intervals.
Steering Wheel 3. Steering shaft flexible coupling 3. Align the column and couplings.
misaligned.
4. Steering gear adjusted too tight. 4. Adjust over-center and thrust bearing
preload to specifications.
5. Front wheel alignment incorrect. 5. Check the alignment and correct as
necessary.
J9219-26
J STEERING 1 9 - 37
PITMAN SHAFT SEAL REPLACEMENT ADJUST WORMSHAFT BEARING PRELOAD

TORQUE
REMOVAL (1) Adjust the preload by tightening the adjuster
(1) Mark pitman arm and shaft positions for refer #
plug. The preload should be 0.6 to 1 N m (5 to 8 in.
ence. Remove pitman arm with Puller 7998 (J6632- lbs.) torque.
01). Steering column/shaft misalignment or damage
(2) Remove the pitman shaft seal with a small will increase the amount of torque required to rotate
blade screw driver. the steering wheel. If the rotating torque is excep
tionally high, inspect the steering column/shaft
INSPECTION alignment. If the alignment is correct, remove the
(1) Inspect the condition of the steering gear lubri steering gear, determine the cause of the high pre
cant. If contaminated (contains metal particles), re load torque, and repair as necessary.
move and overhaul the steering gear. (2) Tighten the adjuster locknut to 68 N*m (50 ft.
INSTALLATION lbs.) torque. Measure the preload torque. If neces
sary, adjust the preload torque again.
(1) Lubricate the new seal with chassis lubricant.
CAUTION: A protective wrap must be used on the

ADJUST OVERCENTER DRAG TORQUE
shaft threads/splines during seal installation. If the
(1) Turn the steering wheel from one stop to the
shaft seals are installed over exposed shaft, the
other and count the total numbers of turns. Turn the
seal lips could be cut or distorted. T h i s can result
wheel back in reverse direction 1/2 the total number
in leakage after installation.
of turns to center the steering gear.
(2) Turn the over center adjusting screw in to re
(2) Wrap a single layer of plastic tape around the move all lash between the ball nut and pitman shaft
pitman shaft threads and splines. This will protect sector teeth. Hold the adjustment screw and tighten
the replacement seals during installation. the lock nut to 34 N*m (25 ft. lbs.) torque.
(3) Install the seal with a suitable size socket. (3) Check the torque at the steering wheel by tak
(4) Remove the tape from the shaft. ing the highest reading as the wheel is turned
(5) Center the steering gear. through the center position.
(6) Align and install the pitman arm. (4) The overcenter drag torque should be 0.5 to 1
(7) Install the washer and retaining nut on the pit N*m (4 to 10 in. lbs.).
man shaft. Tighten the nut to 251 N*m (185 ft. lbs.) (5) If necessary, loosen the lock nut and adjust the
torque. over center adjuster screw to obtain the proper
torque. Re-tighten the lock nut to the lock nut.
GEAR ADJUSTMENTS IN VEHICLE (6) After tightening the locknut, measure the over-
center drag torque again and readjust the torque, if
REMOVE necessary.
(2) Mark the pitman shaft and pitman arm for in INSTALL
stallation reference. Remove the pitman arm from (1) Align the installation reference marks and in
the shaft. stall the pitman arm.
(3) Loosen the adjuster lock nut then back the ad (2) Install and tighten the pitman shaft nut and
juster plug off 1/4 turn. washer to 251 N*m (185 ft. lbs.) torque.
(4) Remove the steering wheel horn pad. (3) Install the horn button.
(5) Turn the steering wheel in one direction until
GEAR DISASSEMBLY
stopped by the gear. Then turn back 1/2 turn.
(1) Rotate the wormshaft from stop-to-stop and
CAUTION: Do not turn the steering wheel hard count the number of rotations. Rotate the wormshaft
against the internal stops when the linkage i s re in the reverse direction 1/2 of the total number of ro
moved. T h i s could result in damage to the recircu tations to center it and the ball nut.
lating ball guides. (2) Remove the pitman shaft adjustment screw
locknut. Remove the cover retaining bolts, cover, and
gasket (Fig. 3).
MEASURE (3) Slide the adjustment screw head (Fig. 3) out of
Place a low calibration (50 in. lbs.) torque wrench the pitman shaft T-slot and remove it and the
and socket on the steering wheel nut. Rotate the shim(s).
wrench and nut through a 90 degree arc (1/4 turn). (4) Retain the shim(s) for end-play measurement
This will measure the worm shaft bearing preload. during assembly.
19 - 38 STEERING
(5) Remove the pitman shaft, the wormshaft bear To aid the recirculating ball installation, rotate
J
ing preload torque adjustment cap locknut, and the wormshaft back and forth slightly while insert
adjustment cap (Fig. 2). ing the balls.
(6) Remove the wormshaft and the ball nut (Fig. (5) Place the ball guide clamp on the ball nut and
2). install the clamp retaining screws. Tighten the
(7) Remove (pry) the pitman shaft and the worm- #
screws to 14 N m (10 ft. lbs.) torque.
shaft seals from the steering gear housing (Fig. 3).
CAUTION: T o avoid damaging the tangs on the ball
WORMSHAFT AND BALL NUT DISASSEMBLY guide ends, do not allow the wormshaft to travel to
(1) Remove the upper bearing from the wormshaft the end of the thread in either direction.
(Fig. 2).
(6) Lubricate the wormshaft threads with chassis
CAUTION: Do not allow the ball nut to rotate freely lubricant. Rotate the shaft to move it in and out of
and travel to either extreme end of the wormshaft. the ball nut and distribute the lubricant.
T h i s could damage the tangs at the ends of the re
(7) Lubricate the wormshaft upper bearing with
circulating ball guides (Fig. 3).
chassis lubricant and install it on the wormshaft.
(2) Remove the recirculating ball guide clamp re
WORMSHAFT BEARING ADJUSTMENT CAP
taining screws, the clamp and the guides (Fig. 2 ) .
Separate the half-guides and place the recirculating DISASSEMBLY
balls aside in a container. (1) Pry out and remove the wormshaft lower bear
(3) Hold the ball nut over a cloth. Remove the re ing retainer from the adjustment cap (Fig. 6).
maining recirculating balls by rotating the worm- (2) Remove the wormshaft lower bearing from the
shaft back and forth. adjustment cap.
There are a total of 50 recirculating balls
within the ball nut and the guides (25 in each CLEANING/INSPECTION
circuit). (1) Clean all the components in cleaning solvent
(4) Remove the wormshaft from the ball nut (Fig. and dry with a clean cloth only.
2). (2) Inspect each component for wear and damage.
Replace as necessary.
(1) Clean all the components in a cleaning solvent WORMSHAFT BEARING ADJUSTMENT CAP
and dry them with a clean cloth and/or compressed ASSEMBLY
air. (1) Remove the lower bearing cup Remover 7837
(2) Inspect each component for wear, scoring, (J-29369-1) and Slide Hammer C-637 (J-2619-01)
cracks, nicks and surface pitting. Replace as neces (Fig. 7). Install a new bearing cup in the cap with a
sary. correct sized socket (Fig. 8).
(2) Lubricate the wormshaft lower bearing and
WORMSHAFT AND BALL NUT ASSEMBLY place it in the bearing cup.
(3) Install the lower bearing retainer on the ad
CAUTION: T h e ball nut teeth are wider and deeper
justment cap. If necessary, tap the retainer lightly
on one side than on the other.
with a plastic mallet to seat it.
(1) Position the ball nut with the recirculating ball
guide holes facing upward and the ball nut teeth fac GEAR CLEANING AND INSPECTION
ing downward. Install the wormshaft in the ball nut. (1) Clean the housing and the pitman shaft with
Rotate the shaft and thread it into the nut until an cleaning solvent and dry them with a clean cloth
equal number of shaft threads are visible at each end and/or compressed air.
of the nut (Fig. 4). (2) Inspect the housing for cracks, porosity, dam
(2) Install one recirculating ball in each ball guide aged threads and scoring/distortion of the gasket sur
hole. Move the wormshaft up/down and side-to-side face area. Repair or replace as necessary.
until the balls roll into the ball nut threads at the (3) Inspect the pitman shaft contact surface and
bottom of wormshaft and support the wormshaft. the teeth for wear, pitting, and other damage. Re
(3) Assemble and install the ball guides in the ball place as necessary.
nut (Fig. 5). (4) Insert the pitman shaft in the steering gear
(4) Divide the remaining 48 recirculating balls housing shaft bore and inspect for excessive shaft or
into two groups and install 24 balls in each ball nut housing shaft bore wear. The shaft should have a
circuit. Insert the balls in the ball nut circuits smooth, bind-free fit with no visible side play when
through the holes in the ball guides (Fig. 5). installed in the shaft bore.
STEERING 19-39
COVER
BEARING
CAP
J8919-12
Fig. 2 Manual Steering Gear—Exploded View

19 - 40 STEERING J
SEALS
J8919-15
Fig. 5 Recirculating Ball Installation

BEARING
RETAINER
Fig. 6 Wormshaft Lower Bearing Retainer Removal

TEETH
DOWNWARD J8919-14
surface. The end-play must not exceed 0.05 mm
(0.002 in). If the end-play exceeds the specified
Fig. 4 Wormshaft & Ball Nut limit, select and install a replacement shim that
(5) If the shaft fit is loose but it is not visibly reduces the end-play to below the specified
worn, trial fit a replacement pitman shaft in the limit.
housing shaft bore. If the replacement shaft also has (7) Inspect the wormshaft shaft upper bearing and
a loose fit, replace the housing. However, if the re bearing cup for wear, looseness, flat spots, pitting,
placement pitman fits properly, replace the original cracks, and other damage. If either the bearing or
pitman shaft. the bearing cup is damaged, both components must
(6) Measure the pitman shaft adjustment screw fit be replaced.
and end-play in the T-slot (Fig. 9). When installed, (8) If the cup fits loosely in the housing, trial fit a
the adjustment screw must rotate freely and not bind replacement cup. If the replacement cup also fits
in any position. Measure the end-play by inserting a loosely, replace the housing. If the replacement cup
feeler gauge between the screw head and the T-slot fits properly, replace only the original bearing cup.
J STEERING 19 - 41
END-PLUG
MEASUREMENT
SPECIAL TOOL
C-637
OR
J-2619-01 J9119-25 J8919-19
Fig. 7 Bearing Cup Removal Fig. 9 Adjustment Screw End-Play Measurement

BEARING
CUP
Fig. 8 Bearing Cup Installation Fig. 10 Wormshaft Upper Bearing Cup Removal
GEAR ASSEMBLY (4) Place the steering gear housing in a vise.
(1) Remove wormshaft upper bearing cup with a Clamp the vise jaws on the housing mounting bosses
hammer and a brass punch (Fig. 10). only.
(2) Install a replacement bearing cup with an ap (5) Install the wormshaft and ball nut in the steer
propriate installation tool (Fig. 11). ing gear housing.
Do not install the wormshaft or the pitman
shaft seals at this time. CAUTION: Ensure that the ball nut is installed with
(3) Lubricate all the components with chassis lu the wide/deep side of the ball nut teeth facing to
bricant. ward the cover opening.
1 i - 42 STEERING
BALL N U T
CENTER GROOVE
Fig. 11 Wormshaft Upper Bearing Cup installation Fig. 12 Pitman Shaft & Ball Nut Engagement
(6) Install the wormshaft bearing adjustment cap ment screw counterclockwise until the cover is tight
in the housing and tighten it only enough to remove against the gasket and then loosen the screw 1/2 ro
the wormshaft end-play. tation.
(7) Install the locknut on the wormshaft bearing (15) Tighten the cover bolts to 61 N*m (45 ft. lbs.)
adjustment cap but do not tighten it at this time. torque.
(8) Pack the steering gear housing with as much (16) Install the pitman shaft seal, refer to the re
chassis lubricant as possible. placement procedure.
Rotate the wormshaft in one direction until the (17) Rotate the wormshaft and observe the steer
ball nut ceases. Pack the end of the housing full ing gear operation. With the adjustment screw and
cap loose, the wormshaft should rotate freely and not
of lubricant, rotate the shaft in the opposite di
bind. If the steering gear binds, repair as necessary.
rection and repeat the packing procedure.
(18) Inspect for lubricant leakage from the shaft
(9) Place the ball nut (Fig. 12) in the centered po
seals. If there is a leak at either seal, replace the de
sition, rotate the wormshaft from stop-to-stop and
fective seal(s).
count the number of rotations. Rotate wormshaft in
the reverse direction 1/2 of the number of rotations GEAR ADJUSTMENTS ON BENCH
to center the ball nut.
(10) Lubricate the pitman shaft with chassis lubri WORM BEARING PRELOAD
cant and insert it in the steering gear housing. En (1) Tighten the worm bearing adjuster plug until it
gage the center tooth on the shaft with the center bottoms, then loosen 1/4 turn.
groove on the ball nut. (2) Carefully turn the wormshaft all the way to
(11) Apply chassis lubricant to the replacement the end of travel, then turn back 1/2 turn.
housing cover gasket. Position it so that it surrounds (3) Tighten adjuster plug until torque wrench indi
the housing cover opening. cates 0.6 to 1,0 N*m (5 to 8 in. lbs.) torque (Fig. 13).
(4) Tighten the adjuster plug locknut to 68 Nnn
(12) Place the shim(s) on the adjustment screw and
thread the screw into the cover to a depth of 2 to 3
threads. OVER'GENTER PRELOAD
(13) Slide the head of the adjustment screw into (1) Back off preload adjuster until it stops, then
the pitman shaft T-slot. With the cover in place, ro turn it in one full turn.
1
tate the screw counterclockwise to thread it into the (2) With gear at center of travel, check torque to
cover. Rotate the screw until the cover almost comes turn stub shaft. This will be reading #1 (Fig. 14).
in contact with the gasket. (3) Turn adjuster in until torque to turn stub shaft
(14) Install the cover retaining bolts and finger is 0.5 to 1 Nnn (4 to 10 in. lbs.) more than reading
tighten them only. Continue tightening the adjust- #1.
J STEERING 19 - 43
ADJUSTMENT T O R Q U E BAR from frame rail to remove shaft. Refer to Steering

CAP W I T H SOCKET WRENCH Gear Replacement in this section.
Fig. 13 Worm Bearing Preload Adjustment

J9119-48
Fig. 15 Coupler Shaft- XJ
Fig. 16 Coupler Shaft— YJ
J8919-24
INSTALLATION
(1) Align the intermediate (coupler) shaft to the
Fig. 14 Over-center Adjustment steering gear and column.
(2) Position the steering gear on the frame. Refer
(4) Hold pitman shaft adjustment screw and to Steering Gear Replacement in this section.
tighten adjuster lock nut to 34 N*m (25 ft. lbs.) (3) Install and tighten the pinch bolts to 34 N»m
torque. (25 ft. lbs.) torque.
INTERMEDIATE (COUPLER) SHAFT STEERING GEAR REPLACEMENT
REMOVAL REMOVAL
(1) Place the front wheels in the straight ahead po (1) Place the front wheels in the straight ahead po
sition. sition with the steering wheel centered.
(2) Remove the shaft pinch bolt at the steering (2) Remove the column coupler shaft from the
gear and column (Fig. 15, 16). Un-bolt steering gear gear. Refer to the removal procedures in this section.
19 - 44 STEERING J

man Arm Removal in the Steering Linkage section.
(4) Remove the steering gear retaining bolts and
nuts. Remove the steering gear from the vehicle (Fig.
17, 18).
FRAME WASHER SCREW
Fig. 18 Steering Gear Mounting— YJ

ADAPTER
MANUAL STEERING GEAR SPECIFICATIONS
GEAR J9219-46
Wormshaft Bearing Preload Torque . . 0.6-0.9 N-m (5 to 8 in-lbs)
Fig. 17 Steering Gear Mounting— XJ
Pitman Shaft Overcenter
INSTALLATION Drag Torque . 0.5-1 N-m (4 to 10 in-lbs)
(in addition to above)
(1) Align the column coupler shaft to steering
gear. Refer to Column Coupler installation in this Maximum Steering Gear Torque . . . . 2 N-m (18 in-lbs)
section. total (maximum)
(2) Position the steering gear (and bracket) on the Steering Gear Lubricant Multi-purpose
frame rail and install the bolts. chassis grease
• X J - Tighten the bolts to 95 N-m (70 ft. lbs.)
Steering Gear Ratio ., 24:1
torque.
• YJ— Tighten the bolts to 105 Nnn (78 ft. lbs.) Steering Gear Type Recirculating Ball
torque.
(3) Align and install the pitman arm. Refer to Pit J9019-2
man Arm Installation in the Steering Linkage sec
tion.
STEERING 19 - 45
STEERING COLUMN GENERAL SER¥ICE
INDEX
page page
Column Replacement— YJ 48 Service Information 45
Column Replacement—XJ . 46 Steering Wheel 45
Park-Lock Cable—Console Shift Automatic . . . . . 45
SERVICE INFORMATION
The column may be disassembled and reassembled.
Also most steering column components can be ser
viced without removing the column from the vehicle.
For additional information, refer to Group 8H, Elec
trical.
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
CAUTION: Disconnect negative (ground) cable from

the battery before servicing any component on the
column.
Safety goggles should be worn at all times

when involved with steering column service.
STEERING WHEEL
REMOVAL
J9219-54
(1) Make sure the front wheels are in the straight
ahead position. Fig. 1 Horn Pad Removal/Installation
(2) Disconnect the negative (ground) cable from
PULLER
the battery.
(3) Remove the horn contact components (Fig. 1).
(4) Remove the steering wheel retaining nut and
the vibration dampener, if equipped. Score or paint
alignment marks on the column shaft and steering
wheel (if none exist) for installation reference.
(5) Remove the steering wheel with Puller 7591 (J-
21232-01) (Fig. 2).
INSTALLATION
(1) Install the steering wheel with the scored or
painted marks aligned.
(2) Install the retaining nut and tighten to 34 N»m
(25 ft. lbs.) torque. Force the steering wheel down
on the shaft with the retaining nut only.
(3) Install the horn contact components (Fig. 1).
(4) Connect the battery ground (negative) cable.
PARK-LOCK CABLE-CONSOLE SHIFT AUTOMATIC

REMOVAL J-8919-113
(2) Remove the lower portion of the instrument Fig. 2 Steering Wheel Removal
panel, refer to Group 8E, Instrument Panel.
19-46 STEERING J
(3) Remove the steering column mounting bracket PARK
to instrument panel nuts. Lower the steering column. GATE
Refer to Steering Column Removal .
(4) Disconnect the park-lock cable from the steer
ing column and bracket. SADDLE
(5) Remove the center console and related trim.
(6) Pull the carpet backward to expose the cable at PAWL
the gear selector lever bell-crank (Fig. 3).
EYELET
J9219-53
Fig. 4 Park-Lock Adjustment

(6) Lower the cable into the mounting bracket un
LOCK
CLAMP
til the tabs are fully engaged in the adjuster (Fig. 3).
(7) Push the cable adjuster lock clamp downward
BELLCRANK to lock it (Fig. 3).
(8) Remove the pin from the park gate.
(9) Test the park-lock cable operation:
• Turn the ignition switch key to the LOCK position
• Press inward on the gear selector handle release
button, the button should not move
• Turn the ignition switch key to the ON position
ADJUSTER J8919-114
button
Fig. 3 Park-Lock Cable • Move the gear selector handle to the DRIVE or
NEUTRAL position
(7) Disconnect the cable eyelet from the bell-crank • Attempt to turn the ignition switch key to the
(Fig. 3). LOCK position
(8) Remove the cable from the shift bracket (Fig. • If the park-lock cable is correctly adjusted, the key
3). will not turn to the LOCK position;
INSTALLATION
button
(1) Route and install the cable.
(2) Position the carpet and install the retaining • Move the gear selector handle to the PARK posi
screws, the accelerator pedal bracket, the panels and tion
the moldings. • Turn the ignition switch key to the LOCK position
(3) Install the center console and related trim. • If the park-lock cable is correctly adjusted, the key
(4) Raise the steering column, refer to Steering will turn to the LOCK position.
Column Removal. (6) If additional cable adjustment is required, slide
(5) Install the lower portion of the instrument the adjuster forward or rearward to obtain the cor
panel, refer to Group 8E, Instrument Panel. rect position (Fig. 3).
(6) Connect the battery negative cable. Refer to Group 21, Transmission for additional in
formation.
ADJUSTMENT
(1) Pry up the park-lock cable adjuster lock (Fig. COLUMN REPLACEMENT-XJ
3).
(2) Connect the park-lock cable eyelet to the bell- REMOVAL
crank pin (Fig. 3).
(3) Place the gear selector in park. CAUTION: Bumping, jolting and hammering on the
(4) Insert a .030 - .035 pin between the pawl and steering column shaft and gear shift tube must be
the park gate (Fig. 4). avoided during all service procedures.
(5) Push the spring-loaded cable adjuster forward.
J STEERING 19 - 47

ahead position.
the battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) Column shift vehicles, disconnect the shift ca
ble grommet by prying it from the shift lever (Fig.
5).
DASH
PANEL
BRACKET
J9119-48
Fig. 6 Column Shaft Coupler
S H I F T CABLE J9219-50
Fig. 5 Shift Cable Grommet

(5) Disconnect the column shaft to steering gear
coupler upper bolt (Fig. 6).
(6) Remove the lower portion of the instrument
(7) Column shift vehicles, disconnect the shift indi
cator cable from the shift housing (Fig. 7).
(8) Remove two nuts holding steering column
bracket to brake sled (Fig. 8).
(9) Remove four bolts holding steering column
bracket to column.
(10) Loosen column brace mounting nut at drivers
side kick panel. This will allow column to drop.
Fig. 7 Indicator Cable Clip
(11) Disconnect the following items from the steer
ing column connectors: INSTALLATION
• Ignition switch wire harness
• Dimmer switch wire harness CAUTION: Bumping, jolting and hammering on the
• Turn signal switch wire harness steering column shaft and gear shift tube must be
• Windshield wiper wire harness avoided during all service procedures.
• Cruise control wire harness (if equipped)
(1) Carefully position column in vehicle.
• Park-lock cable (if equipped)
(2) Align the column shaft to steering gear cou
(12) Remove the bolts that attach the toe plate to
pling. Install and tighten the bolt to 34 N-m (25 ft.
the floor pan (Fig. 9).
lbs.) torque.
(13) Carefully remove column from vehicle.
19 - 4 8 STEERING J
(9) Column shift vehicles, install the shift indica

tor cable on the shift housing. Check operation.
(10) Install the lower portion of the instrument
(11) Install steering wheel on column, refer to
Steering Wheel-Installation.
(12) Connect the negative (ground) cable to the
battery.
COLUMN REPLACEMENT— YJ
REMOVAL
CAUTION: Bumping, jolting and hammering on the

steering column shaft and gear shift tube must be
avoided during all service procedures.

ahead position.
the battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) Column shift vehicles, disconnect the shift ca
ble grommet by prying it from the shift lever.
(5) Disconnect the column shaft to steering gear
coupler upper bolt (Fig. 10).
Fig. 9 Steering Column Mounting

(3) As applicable, connect the following items to
the steering column connectors:
• Dimmer switch wire harness
Fig. 10 Column Shaft Coupler
• Turn signal switch wire harness
• Windshield wiper wire harness (6) Remove the lower portion of the instrument
• Cruise control wire harness (if equipped) panel, refer to Group 8E, Instrument Panel.
• Park-lock cable (if equipped) (7) Remove two nuts holding steering column
(4) Install the support bracket on the column and bracket to brake sled (Fig. 11).
tighten the bolts to 20 N-m (180 in. lbs.) torque. (8) Remove four bolts holding steering column
(5) Raise the column up to the brake sled studs. bracket to column.
Connect the brace to the column stud. (9) Disconnect the following items from the steer
(6) Install and tighten the column to brake sled ing column connectors:
nuts to 30 N-m (22 ft. lbs.) torque. 1
(7) Column shift vehicles, install the shift cable • Dimmer switch wire harness
grommet on the shift lever. • Turn signal switch wire harness
(8) Install and tighten the toe plate-to-floor pan • Windshield wiper wire harness
bolts to 8 N-m ( 6 6 in. lbs.) torque. • Cruise control wire harness (if equipped)
J STEERING 1 9 - 4 9
REMOVE
J9219-52
Fig. 11 Column Bracket Fig. 12 Steering Column Mounting

(10) Remove the bolts that attach the toe plate to • Turn signal switch wire harness
the floor pan (Fig. 12). • Windshield wiper wire harness
(11) Carefully remove column from vehicle. • Cruise control wire harness (if equipped)
(4) Install the support bracket on the column (Fig.
INSTALLATION 11) and tighten the bolts to 30 N*m (270 in. lbs.)
torque.
CAUTION: Bumping, jolting and hammering on the (5) Install and tighten the column to brake sled
steering column shaft and gear shift tube must be bolts (Fig. 11) to 30 N*m (270 in. lbs.) torque.
avoided during all service procedures. (6) Column shift vehicles, install the shift cable
grommet on the shift lever.
(1) Carefully position column in vehicle. (7) Install and tighten the toe plate to floor pan
(2) Align the column shaft to steering gear cou bolts/nuts to 21.5 N-m (192 in. lbs.) torque (Fig. 12).
pling. Install and tighten the bolt to 34 N*m (25 ft. (8) Install the lower portion of the instrument
lbs.) torque. panel, refer to Group 8E, Instrument Panel.
(3) As applicable, connect the following items to (9) Install steering wheel on column, refer to
the steering column connectors: Steering Wheel-Installation.
• Ignition switch wire harness (10) Connect the negative (ground) cable to the
• Dimmer switch wire harness battery.
19-50 STEERING J
NON-TILT STEERING COLUMN
DISASSEMBLY-COLUMN OR CONSOLE SHIFT LOCKPLATE
Steering column removal from the vehicle is not COMPRESSOR
necessary for;
• Lockplate cover
• Lockplate
• Steering shaft retaining ring
• Canceling cam
• Turn signal switch
• Upper bearing preload spring
• Ignition key/lock cylinder service
The steering column must be removed from
the vehicle to service any other component.
(1) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
STEERING
COLUMN
SUPPORT
FIXTURE
J8919-120
Fig. 2 Retaining Snap Ring Removal

CAUTION: When the steering shaft retaining snap
ring i s removed, the steering shaft i s no longer re
tained within the column.
(6) Remove the lockplate, canceling cam, upper

bearing preload spring, and the thrust washer from
the steering column/shaft (Fig. 3).
CANCELING
PRELOAD
CAM
SPRING
LOCKPLATE
J8919-119
Fig. 1 Steering Column Support Fixture

(2) Remove the steering wheel. Refer to the re
moval procedure.
(3) Remove the lockplate cover.
WARNING: T H E L O C K P L A T E R E T A I N S A V E R Y
S T R O N G , S P R I N G F O R C E . DO N O T A T T E M P T T O
R E M O V E T H E S T E E R I N G S H A F T RETAINING S N A P THRUST
WASHER
RING W I T H O U T USING L O C K P L A T E C O M P R E S S O R
C-4156 (J23653-B).
(4) Compress the lockplate with Compressor

C-4156 (J-23653-B) and release the steering shaft re
taining snap ring (Fig. 2).
J8919-121
(5) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring. Fig. 3 Steering Column Disassembly
J STEERING 1 9 - 5 1
(7) Remove the hazard warning switch knob. Press T U R N SIGNAL

the knob inward and remove it from the column by S W I T C H RETAINING
turning it counterclockwise. SCREW
(8) Remove the turn signal/wiper/cruise control
stalk by pulling it out straight from the column.
Wiper must be in the off position.
(9) Disconnect the turn signal wire harness con
nector from the bracket.
CAUTION: Wrap tape around the turn signal

switch wire harness connector (Fig. 4) to prevent it
from becoming entangled during removal.
TAPE
Fig. 5 Turn Signal Switch Retaining Screw

KEY W A R N I N G B U Z Z E R
SWITCH A N D CONTACTS
J8919-122
Fig. 4 Taped Turn Signal Switch Wire Harness

Connector
(10) Remove the turn signal switch retaining
screws (Fig. 5), dimmer switch actuator arm, to re
move the switch. Guide the switch straight up and
out of the steering column.
(11) Remove the wiper switch wire harness and all
the other wire harnesses located within the steering
column. J8919-124
(12) Insert the ignition switch key into the key/
lock cylinder and turn to the ON position. Fig. 6 Key Warning Buzzer/Contacts Removal
CAUTION: Do not attempt to remove the key warn Depress the spring latch located at the bottom of the
ing buzzer switch and contacts separately. If sepa slot to release the key/lock cylinder. Remove the key/
rated, the contacts can detach and drop into the lock cylinder. (Fig. 7).
steering column. (15) Remove the ignition switch and the dimmer
switch (Fig. 8) from the lower end of the steering col
(13) Remove the key warning buzzer switch and umn.
contacts as a unit (Fig. 6). Use needle-nose pliers or Proceed to Column Shift Disassembly Proce
a paper clip bent at a right angle (90 degrees). dure or Console Shift Disassembly Procedure.
(14) Turn ignition key/lock cylinder to the ON po
sition. Insert a thin screwdriver into the slot adjacent
to the switch attaching screw boss (right-hand slot).
19-52 STEERING J
K E Y / L O C K CYLINDER
HOUSING
LOCK C Y L I N D E R ^
^Pk^ ^ RB24
Fig. 7 Key/lock Cylinder Removal

IGNITION
SWITCH
ADJUSTMENT J8919-126
HOLE
Fig. 9 Key/Lock Cylinder Housing
S H I F T LEVER IGNITION
D E T E N T PLATE SWITCH
ACTUATING R O D
A N D RACK
ASSEMBLY
THRUST
CAP
DIMMER SHAFT
J8919-116 LOCK BOLT
SWITCH
A N D SPRING
ASSEMBLY
Fig. 8 Ignition Switch & Dimmer Switch
COLUMN SHIFT DISASSEMBLY
(1) Remove the gear selector lever upper pivot pin
and the selector lever. J8919-127
(2) Remove the upper bearing thrust washer.
(3) Remove the four screws that attach the key/ Fig. 10 Key/Lock Cylinder Housing Components
lock cylinder housing to the steering column jacket. (7) Use a blunt punch to exert force on the block
Remove the housing (Fig. 9). tooth to disengage and remove the lock sector (Fig.
(4) Remove the thrust cap from the key/lock cylin 11).
der housing (Fig. 10). (8) Remove the gear selector lever housing and the
(5) Remove the ignition switch actuating rod and shroud from the steering column jacket.
rack from the key/lock cylinder housing (Fig. 10). (9) Remove the gear selector lever spring from the
(6) Remove the rack preload spring and the shaft lever housing.
lock bolt and spring from the key/lock cylinder hous T h e steering column must be removed from
ing. Remove the shift lever detent plate from the the vehicle to disassemble the remaining steer
housing (Fig. 10). ing column components.
J STEERING 1S - 53
J8919-128
Fig. 11 Lock Sector Removal Fig. 13 Key/Lock Cylinder Housing Removal

(10) Remove the steering shaft (if not previously (4) Remove the key/lock cylinder housing-to-shroud
removed). attaching screws (Fig. 14). Separate the housing and
(11) Remove the spring clip from the steering col the shroud.
umn lower bearing retainer. Remove the retainer,
the lower bearing and the adapter (Fig. 12).
L O W E R BEARING,
RETAINER, CLIP
A N D ADAPTER
J8919-129
Fig. 12 Lower Bearing, Adapter, Retainer & Clip J8919-131

(12) Slide out and remove the shift tube.
Fig. 14 Housing/Shroud Attaching Screw
CONSOLE SHIFT DISASSEMBLY
(5) Remove the wave washer from the key release
(1) Remove the screws that attach the key/lock cyl
lever pivot. Remove the key release lever and the
inder housing and the shroud to the steering column
pivot.
jacket (Fig. 13).
(6) Remove the lock rack and the lock bolt (Fig.
(2) Remove the dimmer switch actuator arm.
15).
(3) Disengage the remote rod from the lock rack.
(7) Remove the lock rack preload spring.
19 - 54 STEERING J
(10) Remove the spring clip from the lower bearing

retainer. Remove the retainer, the bearing and the
adapter (Fig. 17).
L O W E R BEARING,
RETAINER, CLIP
A N D ADAPTER
J8919-129
Fig. 17 Lower Bearing Components

Fig. 15 Lock Rack & Lock Bolt
ASSEMBLY
(8) Use a blunt punch to exert force on the block Proceed to Column Shift Assembly Procedure
tooth to disengage and remove the lock sector (Fig. or Console Shift Assembly Procedure.
16).
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. THIS WILL ENSURE THE COL
UMN WILL BREAKAWAY WITH IMPACT.
CAUTION: Apply chassis lubricant to all the bear

ing, thrust and friction producing mating surfaces
before assembly.
COLUMN SHIFT ASSEMBLY

(1) Insert the lock sector through the key/lock cyl
inder hole in the key/lock cylinder housing. Install
the lock sector on the lock sector shaft (Fig. 18). En
sure that the lock sector turns freely after installa
J8919-128 tion.
(2) Install the lock rack preload spring. The bowed
Fig. 16 Lock Sector Removal side of the spring must contact the lock rack when
The steering column must be removed from the rack is installed.
the vehicle to disassemble the remaining steer (3) Assemble the lock bolt and the lock rack (Fig.
ing column components. 19).
(4) Install the assembled lock bolt and lock rack in
(9) Remove the steering shaft (if not previously re
the key/lock cylinder housing (Fig. 20). Mate the lock
moved).
rack block tooth with the lock sector block tooth.
(5) Install the shift lever detent plate on the key/
lock cylinder housing (Fig. 21).
J STEERING 1 9 - 55
LOCK
RACK
BLOCK
TOOTH
J8919-135
Fig. 18 Lock Sector Installation Fig. 20 Lock Bolt/Lock Rack Installation

LOCK
S H I F T LEVER IGNITION
RACK
D E T E N T PLATE SWITCH
LOCK
BOLT
J8919-134 J8919-127
Fig. 19 Lock Bolt & Lock Rack Fig. 21 Key/Lock Cylinder Housing
(6) Install the thrust cap on the key/lock cylinder (10) Install the gear selector lever housing and
housing (Fig. 21). shroud on the upper end of the steering column
(7) Install the ignition switch actuating rod and jacket. Rotate the housing and ensure that the bear
rack on the key/lock cylinder housing. ing is properly seated.
(8) Insert and install the gear selector lever hous (11) Place the gear selector in the PARK position,
ing lower bearing the housing. Align the indenta and the lock rack pulled downward. Position and cor
tions in the bearing shell with the projections on the rectly seat the key/lock cylinder housing on the
housing jacket. steering column jacket. Install and tighten the four
(9) Install the gear selector lever spring in the le attaching screws.
ver housing.
19 - 56 STEERING J
(12) Insert the shift tube in the lower end of the LOCK
steering column jacket. Rotate it until the shift tube RACK
upper key slides into the gear selector housing key-
way.
CONSOLE SHIFT ASSEMBLY

(1) Insert the lock sector through the key/lock cyl
inder hole in the cylinder housing. Install the lock
sector on the lock sector shaft (Fig. 22). Ensure that
the lock sector turns freely after installation.
LOCK
BOLT
J8919-134
Fig. 23 Lock Bolt & Lock Rack
LOCK
RACK
Fig. 22 Lock Sector Installation
(2) Install the lock rack preload spring. The bowed

side of the spring must contact the lock rack when
the rack is installed.
(3) Assemble the lock bolt and the lock rack (Fig.
23).
(4) Install the assembled lock bolt and lock rack in BLOCK
the cylinder housing (Fig. 24). Mate the lock rack TOOTH
block tooth with the lock sector block tooth.
(5) Install the key-release lever return spring over
the threaded pivot post on the cylinder housing (Fig.
J8919-135
25).
(6) Insert the key-release lever finger into the lock
Fig. 24 Lock Bolt/Lock Rack Installation
rack slot. Position the hole in the lever over the
threaded pivot post on cylinder housing (Fig. 26). En screws to 2 N»m (18 in. lbs.) torque. Ensure that the
sure that the inner end of the spring contacts the re wave washer (Fig. 27) is not displaced while at
lease lever. taching the shroud to the cylinder housing.
(7) Raise the key-release lever slightly. Install the (10) Insert the short, hooked end of the remote rod
end of the lever spring between the lever and the in the lock rack.
boss on the housing (Fig. 27). (11) Install the assembled key/lock cylinder hous
(8) Apply chassis lubricant to the wave washer ing and shroud on the steering column jacket. Install
(Fig. 27). Position it on the threaded pivot post and the attaching screws (Fig. 28). Tighten the screws to
resting on the release lever. 7 N»m (60 in. lbs.) torque.
(9) Position the shroud on the key/lock cylinder
housing and install the attaching screws. Tighten the
STEERING 19-57
WAVE
WASHER
J8919-136
J8919-138
Fig. 25 Key-Release Lever Return Spring Fig. 27 Spring Positioning & Wave Washer
Installation
FINGER THREADED
POST
J8919-137 H O U S I N G ATTACHING
J8919-130
SCREW
Fig. 26 Key-Release Lever Installation
Fig. 28 Key/Lock Cylinder Housing Installation
COLUMN SHIFT OR CONSOLE SHIFT FINAL
ASSEMBLY (2) Install the key warning buzzer switch.
(1) To install ignition switch lock, turn the key to (3) Install the ignition switch, refer to Ignition
the LOCK position and remove the key. This will Switch —All Models in Group 8D, Ignition.
cause the buzzer operating lever to retract in the (4) Install the lower bearing, the adapter, the re
key/lock cylinder. Now insert the key/lock cylinder tainer and spring clip at the lower end of the steer
into the housing far enough to contact the drive shaft ing column.
(Fig. 29). Force it inward and move the ignition (5) Install the steering shaft through the lower end
switch actuator rod up and down to align the compo of the steering column and insert it into the upper
nents. When the components align, the key/lock cyl bearing.
inder will move inward and lock in place.
19-58 STEERING J
KEY/LOCK CANCELING
CYLINDER
J9119-35
Fig. 29 Key/Lock Cylinder Installation Fig. 30 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.
(7) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer
ing column jacket.
(8) Align the turn signal switch in the housing and
secure the switch with the attaching screws. Tighten
the screws to 4 N*m (35 in. lbs.) torque.
(9) Install the dimmer switch actuator arm.
Tighten the attaching screws to 4 N V m (35 in. lbs.)
torque.
(10) If equipped, install the cruise control wire
harness. Install the turn signal stalk by pushing it
straight into the column.
(11) Position the thrust washer, the upper bearing
preload spring and the canceling cam on the steering
shaft (Fig. 30).
(12) Place the turn signal switch in the neutral
(OFF) position and install the hazard warning switch Fig. 31 Lockplate Snap Ring Installation
knob.
(15) Ensure that the retaining snap ring is com
(13) Position the lockplate on the steering shaft.
pletely seated in the groove before removing the tool.
Install a replacement lockplate retaining snap ring
Remove the tool and install the lockplate cover.
on the sleeve of the Lock Plate Compressor C-4156 (16) Install the steering wheel. Refer to the instal
(J-23653-B). Install the tool on the steering shaft lation procedure. Tighten the steering wheel retain
(Fig. 31). ing nut to 34 N*m (25 ft. lbs.) torque.
(14) Compress the lockplate with the compressor (17) If removed, install the steering column in the
tool and position the retaining snap ring in the steer vehicle. Refer to the installation procedure.
ing shaft groove. (18) If disconnected, connect the battery negative
cable and, if equipped, reset the clock
J STEERING 19-59
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).
RING J8919-142
Fig. 2 Lockplate Snap Ring Removal

(11) Remove the hazard warning switch knob.
Press the knob inward and remove it from the steer
J8919-119 ing column by turning it counterclockwise.
(12) If the steering column is the column shift
Fig. 1 Steering Column Support Fixture type, remove the two retaining screws and the gear
(3) If the steering column has not been removed selector indicator cover.
from the vehicle, place the front wheels in the (13) If the steering column is the column shift
straight-ahead position. Disconnect the battery nega type, remove the gear selector indicator lamp bracket
tive cable. retaining screw. Do not remove the lamp and bracket
(4) Protect the painted areas on the steering col at this time.
umn. (14) Remove the tilt-release lever.
(5) Remove the steering wheel. Refer to the re (15) Disconnect the turn signal wire harness con
moval procedure. nector from the bracket located at the lower end of
(6) Column shift: Remove the gear selector lever the steering column (Fig. 3).
retaining pin and the lever from the housing.
CAUTION: Wrap tape around the turn signal switch
(7) Remove the lockplate cover. Use two small pry
wire harness connector to prevent it from becoming
bars to pry the cover off the lockplate.
entangled during removal.
WARNING: T H E L O C K P L A T E R E T A I N S A V E R Y
(16) Remove the plastic protector from the wire
S T R O N G , S P R I N G F O R C E . DO NOT A T T E M P T T O
harness.
R E M O V E T H E S T E E R I N G S H A F T RETAINING S N A P
RING W I T H O U T USING L O C K P L A T E C O M P R E S S O R
(17) Remove the turn signal switch retaining
C-4156 (J-23653-B). screws (Fig. 4), dimmer switch actuator arm, to re
move the switch. Guide the switch straight up and
(8) Compress the lockplate with Lock Plate Com out of the steering column.
pressor C-4156 (J-23653-B) and release the steering (18) Remove the windshield wiper switch wire har
shaft retaining snap ring (Fig. 2). ness and all the other wire harnesses located within
(9) Remove the lockplate compressor tool and the the steering column.
retaining snap ring. Discard the snap ring. (19) Insert the ignition switch key into the key/
(10) Remove the lockplate, canceling cam, upper lock cylinder. Turn the key to the ON position.
bearing preload spring, and the thrust washer from
the steering column/shaft.
J8919-143
J8919-124
Fig. 3 Turn Signal Switch Wire Harness Connector
Fig. 5 Key Warning Buzzer/Contacts Removal
T U R N SIGNAL Depress the spring latch located at the bottom of the
S W I T C H RETAINING
SCREW
slot to release the key/lock cylinder. Remove the cyl
inder (Fig. 6).
Fig. 6 Key/lock Cylinder Removal

Fig. 4 Turn Signal Switch Removal (22) Remove the ignition switch and dimmer
switch (Fig. 7) from the lower end of the steering col
CAUTION: Do not attempt to remove the key warn
umn.
ing buzzer switch and contacts separately. If sepa
(23) Remove the screws that attach the key/lock
rated, the contacts can detach and drop into the
cylinder housing cover to the steering column jacket.
steering column.
Remove the cover.
(20) Remove the key warning buzzer switch and (24) Remove the upper bearing race and the bear
contacts as a unit (Fig. 5). Use needle-nose pliers or ing seat from the steering shaft (Fig. 8).
a paper clip bent at a right angle (90 degrees). (25) Install the tilt-release lever and place the
(21) Turn ignition key/lock cylinder to the ON po steering column in the full upward tilt position.
sition. Insert a thin screwdriver into the slot adjacent
WARNING: T H E T I L T S P R I N G G U I D E R E T A I N E R R E
to the switch attaching screw boss (right-hand slot).
TAINS STRONG SPRING FORCE.
J STEERING 19 - 61
IGNITION
SWITCH
ADJUSTMENT
HOLE
GUIDE
AND
RETAINER
SPRING J8919-145
Fig, 9 Retainer/Guide/Spring Removal

DIMMER TOOL 7101
J8919-116
SWITCH (J21854-01)
Fig. 7 Ignition Switch & Dimmer Switch

RACE SEAT
J9019-3
Fig. 10 Pivot Pin Removal

(29) L i f t the tilt-release lever to release the lock
shoes. Pull the key/lock cylinder housing upward to
disengage the shoes. T u r n the housing clockwise to
separate the lock rack from the remote rod. Remove
the cylinder housing from the support (Fig. 11).
(30) Remove the tilt-release lever from the key/
J8919-144 lock cylinder housing.
(31) Remove the lock sector spring retaining screw
Fig. 8 Steering Shaft Bearing Race & Seat and then remove the spring (Fig. 12). Rotate the
(26) Press the tilt spring guide retainer inward. spring in a clockwise direction to remove i t from the
T u r n i t counterclockwise until the tabs disengage lock bolt.
from the key/lock cylinder housing lugs. Ensure that (32) Remove the lock bolt, the lock rack, the rack
the screwdriver blade properly fits the retainer slot. preload spring and the remote rod from the cylinder
Remove the tilt spring guide retainer, the guide and housing.
the spring from the housing (Fig. 9). (33) Insert a wedge between the lock shoes and the
(27) Position the steering column in the center, key/lock cylinder housing (Fig. 13). This will relieve
non-tilt position. spring tension on the tilt-release lever pin and lock
(28) Remove the support pivot pins with Pivot Pin shoe pin.
Remover C-4016 (J-21854-01) (Fig. 10).
19 - 62 STEERING
J
J8919-147
Fig. 11 Key/Lock Cylinder Housing Removal Fig. 13 Wedge Between Lock Shoes & Housing
J8919-150
Fig. 12 Lock Sector Spring Removal Fig. 14 Tilt-release Lever Pin Removal
(34) Remove the tilt-release lever pin from the (37) Remove the steering shaft from the upper end
key/lock cylinder housing with a standard pin punch of the steering column.
(Fig. 14). (38) Separate the steering shaft by folding it 90 de
(35) Remove the lock shoe pin from the key/lock grees at the flexible joint. Detach the upper and the
cylinder housing with a standard pin punch (Fig. 15). lower shaft halves (Fig. 16).
Remove the lock shoes, the springs and wedge. (39) Remove the attaching bolts and the steering
(36) Remove the upper and the lower bearings and column support (Fig. 17).
races from the key/lock cylinder only if they are (40) Remove the retaining screws and shift gate
damaged or worn. If the bearings and the races must from the steering column support.
be replaced, remove them with a hammer and punch. (41) Remove the retainer and the bearing from the
Discard the bearings and races after removal. They lower end of the steering column.
are not reusable.
J STEERING 19 - 63
PIN SUPPORT
Fig. 15 Lock Shoe Pin Removal Fig. 17 Steering Column Support Removal
UPPER STEERING FLEXIBLE

J
SHAFT-HALF OINT
J8919-154
LOWER
STEERING
Fig. 18 Shift Tube Removal
SHAFT-HALF J8919-152
• Remove the shift bowl from the steering column
Fig. 16 Steering Shaft Separation jacket
(42) Remove the shift tube retaining ring and the (46) If equipped with a console shift, remove the
thrust washer. key-release lever and the lever spring from the
(43) Remove the shift tube from the steering col shroud. Tilt the lever forward and lift upward to re
umn jacket with Shift Tube Remover C - 4 1 2 0 move it (Fig. 20).
(J-23072) (Fig. 18).
(44) Tilt the upper end of the retainer plate toward
the lower end of the column, turn the plate counter
clockwise and remove it (Fig. 19).
(45) If equipped with a column shift:
• Remove the wave washer and the shift tube spring
19---64 STEERING J
CAUTION: Apply chassis lubricant t o all t h e bear

ing, thrust and friction producing mating surfaces
before assembly.
COLUMN SHIFT ASSEMBLY

(1) Install the shift bowl on the steering column
jacket.
(2) Install the shift tube spring, wave washer and
retainer plate in the shift bowl.
(3) Insert the shift tube through the lower end of
the steering column jacket. Align the tube key/spline
with the shift bowl keyway.
(4) Insert the Shift Tube Installer C-4119 (J-23073-
01) in the shift tube. The spring-loaded lower foot of
the tool must engage the shift tube inner shoulder.
The tool guide must be seated in the shift tube (Fig.
21).
(5) Tighten the nut on the stud (Fig. 21) only
enough to obtain a snug fit against the spring ten
sion.
Fig. 19 Retainer Plate Removal NUT
STUD J8919-157
Fig. 21 Shift Tube Installation

Fig. 20 Key-Release Lever & Spring Removal (6) Remove the nut and place the receiver installa
tion tool over the stud (Fig. 22).
ASSEMBLY (7) Install the nut and tighten it to force the shift
WARNING: USE ONLY THE ORIGINAL OR EXACT
tube into the shift bowl (Fig. 22).
REPLACEMENT SCREWS, BOLTS AND NUTS TO
(8) Remove the shift tube installation tools.
ASSEMBLE THE STEERING COLUMN. INCORRECT
(9) Install the shift tube thrust washer and the re
SCREW OR BOLT LENGTH COULD PREVENT THE
tainer plate snap ring.
COLUMN FROM COMPRESSING WITH IMPACT
(10) Install the lower bearing in the steering col
(FRONT-END COLLISION). ALL FASTENERS USED
umn.
FOR ASSEMBLY MUST BE TIGHTENED WITH THE (11) Position the shift gate in the steering column
CORRECT TORQUE. THIS WILL ENSURE THE COL support. Install the attaching screws.
UMN WILL BREAKAWAY WITH IMPACT. (12) Position the support in the steering column.
STEERING 19-65
J (24) Align the pivot pin holes in the housing with
those in the support. Insert the pivot pins. Press the
housing firmly downward when inserting the
pivot pins. This prevents damaging the holes in
the support. When the pivot pins are within both
the housing and the support holes, seat them fully
with a punch and a hammer.
(25) Insert the tilt-release lever in the key/lock cyl
inder housing and place the housing in the full-up
ward tilt position.
(26) Lubricate the tilt spring guide and the tilt
spring liberally with chassis lubricant and position
the spring on the guide.
(27) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down
ward and turning clockwise with a screwdriver.
(28) Place the cover on the key/lock cylinder hous
STUD J8919-158 ing. Align and install the cover retaining screws.
Tighten the screws to 7 N®m (60 in. lbs.) torque.
Fig. 22 Shift Tube Installation (29) Install the gear selector indicator lamp
(13) Install all support attaching screws finger- mounting bracket screw.
tight. Next, tighten the screws alternately and (30) Install the gear selector indicator cover and
evenly to 7 N*m (60 in. lbs.) torque. retaining screws.
(14) Install the remote rod in the support. Route (31) Route the dimmer switch wire harness and
the rod through the upper end of the shroud and in gear selector indicator down through the steering col
sert it into the rod slot located in the support. umn.
(15) Install the dimmer switch and ignition switch. (32) To install ignition switch lock, turn the key to
(16) Install the steering shaft in the steering col the LOCK position and remove the key. This will
umn. cause the buzzer operating lever to retract in the
(17) Install replacement races and bearings in the key/lock cylinder. Now insert the key/lock cylinder
key/lock cylinder, if removed. Ensure that the bear into the housing far enough to contact the drive
ings are lubricated with chassis lubricant before shaft. Force it inward and move the ignition switch
installation. actuator rod up and down to align the components.
(18) Install the lock shoes, the lock shoe springs When the components align, the key/lock cylinder
and the lock shoe pin the key/lock cylinder housing. will move inward and the spring-loaded retainer will
Use a 4.5-mm (0.18-in) diameter rod to align the snap and lock it in place (Fig. 23).
shoes and the pin during installation. (33) Insert the ignition key in the cylinder and
(19) Install the tilt-release lever, the lever spring turn it to the ON position. Install the key warning
and the lever pin in the key/lock cylinder housing. buzzer switch.
Insert a wedge between the housing and the lever to (34) Install the turn signal switch. Fold the wires
relieve the spring tension. This will allow easier re against the connector. Route the wire harness and
lease lever pin installation. connector down through the steering column. Posi
(20) Install the lock bolt in the key/lock cylinder tion the switch in the key/lock cylinder housing. Do
housing and engage it in the lock sector cam surface. not install the switch retaining screws at this time.
(21) Install the lock rack, the rack preload spring (35) Install the windshield wiper wire harness and
and a replacement shim in the key/lock cylinder switch. Route the wire harness down through steer
housing. Align and mate the square block tooth on ing column jacket.
the lock rack and the lock sector. (36) If equipped, install the cruise control wire
(22) Install the lock spring and the spring retain harness. Install the turn signal stalk by pushing it
ing screw. Tighten the screw to 4 N*m (35 in. lbs.) straight into the column.
torque. (37) Insert the hazard warning knob in the hazard
(23) Align and install the assembled key/lock cyl warning switch and press it inward. Align and in
inder housing on the support. Retain the lock shoes stall the turn signal switch retaining screws. Ensure
in the disengaged position for easier housing instal that the turn signal switch is properly seated before
lation. tightening the screws. Tighten the screws to 4 N T H
19 - 66 STEERING J
KEY/LOCK (41) Compress the lockplate with the compressor

CYLINDER tool and position the retaining snap ring in the steer
ing shaft groove.
(42) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be
fore removing the tool.
(43) Position the wire harness protectors, if
equipped, over the wire harnesses and snap them in
place on the steering column.
(44) Install the lockplate cover.
(45) Install the gear selector lever and the retain
ing pin.
(46) Install the steering wheel. Refer to the instal
lation procedure.
(47) Insert the ignition key in the key/lock cylin
der; turn the cylinder to the OFF-UNLOCK position
; move the ignition switch downward to eliminate
any switch-to-remote rod lash; and tighten the igni
tion switch attaching screws to 4 N*m (35 in. lbs.)
torque.
J9119-35
(48) Depress the dimmer switch slightly and insert
Fig. 23 Key/Lock Cylinder Installation a 3/32-inch drill bit into the adjustment hole.
(49) Loosen the retaining screws and move the
(33 in. lbs.) torque. Thread the hazard warning
dimmer switch toward the steering wheel. Tighten
switch knob into the switch and pull the knob out
the dimmer switch retaining screws to 4 N*m (35 in.
ward.
lbs.) torque.
(38) Install and seat the upper bearing race in the
(50) Remove the drill bit and test operation by
key/lock cylinder housing.
moving the dimmer switch stalk. Test the dimmer
(39) Install the upper bearing preload spring, the
canceling cam and the lockplate. switch operation in the full-up, down and center
(40) Install a replacement lockplate retaining snap steering wheel positions.
ring on the sleeve of the Lock Plate Compressor (51) Install the steering column, if applicable. Re
C-4156 (J-23653-B). Install the tool on the steering fer to the installation procedure.
shaft (Fig. 24). CONSOLE SHIFT ASSEMBLY
(1) Position the key-release lever spring on the le
ver and install the lever with the spring in the
shroud.
(2) Align and install the shroud on the steering
column jacket.
(3) Install the retainer plate. Tilt the plate toward
the 12 o'clock position, slide it under the steering col
umn jacket opening, and seat it in the jacket notches.
(4) Align the steering column jacket V-notch with
the corresponding V on the support. Install the sup
port in the steering column. To completely seat the
support, press the key-release lever downward while
pressing the support into place (Fig. 25).
(5) Install all the support retaining screws finger-
tight. Next, tighten the screws alternately and
evenly to 7 N*m (60 in. lbs.) torque.
(6) Install the remote rod in the support. Route the
rod through the upper end of the shroud and insert it
into the rod slot located in the support.
(7) Install the dimmer switch and the ignition
switch.
(8) Install the steering shaft in the steering col
Fig. 24 Lockplate Retaining Ring Installation umn.
J STEERING 19 - 67
(17) Insert the tilt-release lever in the key/lock cyl

inder housing and place the housing in the full-up
ward tilt position.
(18) Lubricate the tilt spring guide and the tilt
spring liberally with chassis lubricant and position
the spring on the guide.
(19) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down
ward and turning clockwise with a screwdriver.
(20) Place the cover on the key/lock cylinder hous
ing. Align and install the cover retaining screws.
Tighten the screws to 7 N»m (60 in. lbs.) torque.
(21) Route the dimmer switch wire harness down
through the steering column.
(22) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
Fig. 25 Steering Column Support Installation shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
(9) Install replacement races and bearings in the When the components align, the key/lock cylinder
key/lock cylinder, if removed. Ensure that the bear will move inward and the spring-loaded retainer will
ings are lubricated with chassis lubricant before snap and lock it in place (Fig. 26).
installation.
KEY/LOCK
(10) Install the lock shoes, the lock shoe springs
CYLINDER
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(11) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re
lease lever pin installation.
(12) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(13) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. The square block tooth on the lock rack and
lock sector must mate.
(14) Install the lock spring and the spring retain
ing screw. Tighten the screw to 4 N»m (35 in. lbs.)
torque.
(15) Align and install the assembled key/lock cyl
inder housing on the support. Retain the lock shoes J9119-35
in the disengaged position for easier housing instal
lation. Fig. 26 Key/Lock Cylinder
(16) Align the pivot pin holes in the key/lock cyl (23) Insert the ignition key in the cylinder and
inder housing with those in the support and insert turn it to the ON position. Install the key warning
the pivot pins. Press the housing firmly down buzzer switch.
ward when inserting the pivot pins to prevent (24) Install the turn signal switch. Fold the wires
damaging the holes in the support. When the against the connector. Route the wire harness and
pivot pins are within both the housing and the sup connector down through the steering column. Posi
port holes, seat them fully with a punch and a ham tion the switch in the key/lock cylinder housing. Do
mer. not install the switch retaining screws at this time.
1 i - 68 STEERING J
(25) Install the windshield wiper wire harness and

switch. Route the wire harness down through steer
ing column jacket.
(26) If equipped, install the cruise control wire
harness. Install the turn signal stalk by pushing it
straight into the column.
(27) Insert the hazard warning knob in the hazard
warning switch and press it inward. Align and in
stall the turn signal switch retaining screws. Ensure
that the turn signal switch is properly seated before
tightening the screws. Tighten the screws to 4 N«m
(33 in. lbs.) torque. Thread the hazard warning
switch knob into the switch and pull the knob out
ward,
(28) Install and seat the upper bearing race in the
key/lock cylinder housing.
(29) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(30) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor
C-4156 (J-23653-B). Install the tool on the steering Fig. 27 Lockplate Retaining Ring Installation
shaft (Fig. 27).
any switch-to-remote rod lash; and tighten the igni
(31) Compress the lockplate with the compressor
tion switch attaching screws to 4 Nnn (35 in. lbs.)
tool and position the retaining snap ring in the steer
torque.
ing shaft groove. (37) Depress the dimmer switch slightly and insert
(32) Remove the compressor tool. Ensure that the a 3/32-inch drill bit into the adjustment hole.
retaining ring is completely seated in the groove be (38) Loosen the retaining screws and move the
fore removing the tool. dimmer switch toward the steering wheel to remove
(33) Position the wire harness protectors, if any lash. Tighten the dimmer switch retaining
equipped, over the wire harnesses and snap them in screws to 4 N*m (35 in. lbs.) torque.
place on the steering column. (39) Remove the drill bit and test operation by
(34) Install the lockplate cover. moving the dimmer switch stalk. Test the dimmer
(35) Install the steering wheel. Refer to the instal switch operation in the full-up, down and center
lation procedure. steering wheel positions.
(36) Insert the ignition key in the key/lock cylin (40) Install the steering column and steering
der; turn the cylinder to the OFF-UNLOCK position wheel. Refer to the installation procedure.
; move the ignition switch downward to eliminate (41) Connect the battery negative cable.
STEERING 19-69
POWER STEERING GEAR STEERING LINKAGE-YJ
Adjustment Plug Initial Adjustment . . 1 0 9 N m ( 8 0 f t . lbs.) D r a g Link to T i e R o d N u t 4 7 N-m ( 3 5 ft. lbs.)

Adjustment Plug Locknut 1 0 9 N m ( 8 0 f t . lbs.) D r a g Link to Pitman A r m N u t 7 4 N-m ( 5 5 ft. lbs.)
Adjustment Screw Locknut . . . . . . . . 4 9 N-m ( 3 6 f t . lbs.) D r a g Link Adjustment Clamp N u t . . . 2 7 N - m ( 2 0 f t . lbs.)
Coupler S h a f t Pinch Bolts . . . . 4 7 N m (35 f t . lbs.) Pitman A r m (Shaft) N u t . 2 5 1 N-m (185 f t . lbs.)
G e a r to Frame Bolts (XJ) » 9 5 N m (70 ft. lbs.) S t e e r i n g Dampener to A x l e
G e a r to Frame Bolts (YJ) . 1 0 6 N-m (78 f t . lbs.) Bracket N u t . 7 4 N-m ( 5 5 f t . lbs.)
Pitman A r m (Shaft) N u t . 2 5 1 N m (185 f t . lbs.) S t e e r i n g Dampener to T i e
Return G u i d e Clamp Screw 5 8 N-m (43 i n . lbs.) Rod N u t 74 N m ( 5 5 f t . lbs.)
Rack-Piston Plug . . 102 N m (75 f t . lbs.) T i e R o d to Steering Knuckle N u t . . . 4 7 N - m ( 3 5 ft. lbs.)
S i d e Cover Bolts 6 0 N-m (44 ft. lbs.) T i e R o d Adjustment Clamp N u t 4 9 N-m ( 3 6 ft. lbs.)
J9319-82 J9319-85
MANUAL STEERING GEAR POWER STEERING PUMP
Adjustment Locknut . 68 N-m (50 ft. lbs.) Bracket to Block Bolts 4 7 N - m ( 3 5 ft. lbs.)
Adjustment Screw Locknut . . 34 N-m (25 ft. lbs.) Pump to Adjustment Bracket 2 8 N - m (21 ft. lbs.)
Return Guide Clamp Screw 14 N-m (10 in. lbs.) F l o w Control Valve to Pump B o d y . . 7 5 N - m ( 5 5 f t . lbs.)
S i d e Cover Bolts . 61 N-m (45 ft. lbs.) H i g h Pressure Fluid Fitting
Adjustment Screw Locknut . . . . . . . . 3 4 N-m (25 ft. lbs.) at Pump and G e a r . . 2 8 N - m (21 f t . lbs.)
G e a r to Frame Bolts ( X j )
v 95 N-m (70 ft. lbs.) Return F l u i d Fitting at G e a r 2 8 N - m (21 f t . lbs.)
G e a r to Frame Bolts (YJ) 106 N-m (78 ft. lbs.)
J9319-83 J9319-86
STEERING LINKAGE—XJ STEERING COLUMN-XJ
D r a g Link to Steering Steering W h e e l to Column

Knuckle N u t . 4 7 N-m (35 ft. lbs.) Shaft Nut 35 N-m (26 f t . lbs.)
D r a g Link to Pitman A r m N u t . 7 4 N-m (55 f t . lbs.) Toe Plate B o l t s / N u t s . 8 Nm ( 6 6 i n . lbs.)
D r a g Link Adjustment Clamp N u t . . . 4 9 N-m ( 3 6 ft. lbs.) U p p e r Bracket S u p p o r t S t u d / N u t s . . 30 N-m ( 2 2 f t . lbs.)
Pitman A r m (Shaft) N u t . . 2 5 1 N m (185 f t . lbs.) S u p p o r t Plate to Column 20 N-m (180 i n . lbs.)
Steering Dampener to A x l e Coupler S h a f t to Column 34 Nm (25 f t . lbs.)
Bracket N u t 7 4 N m (55 ft. lbs.)
Steering Dampener to D r a g
Link N u t 7 4 N m (55 f t . lbs.) J9319-87
T i e R o d to Steering Knuckle N u t . . . 4 7 N-m ( 3 5 f t . lbs.)
T i e R o d Clamp N u t 2 7 N-m ( 2 0 f t . lbs.) STEERING COLUMN-YJ
J9319-84 DESCRIPTION TORQUE
S t e e r i n g W h e e l to Column
Shaft Nut 34 Nm ( 2 5 f t . lbs.)
Toe Plate B o l t s / N u t s 21 N-m (192 i n . lbs.)
U p p e r Bracket S u p p o r t Bolts 30 N-m ( 2 7 0 i n . lbs.)
S u p p o r t Plate to Column 30 N-m ( 2 7 0 i n . lbs.)
Coupler S h a f t to Column . . . . . 34 N-m ( 3 0 0 i n . lbs.)
J9319-88
J TRANSMISSION AND TRANSFER CASE 21 • 1
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
32RH AUTOMATIC TRANSMISSION 66 NP231 TRANSFER CASE 265

AW-4 AUTOMATIC TRANSMISSION . . . . . . . 147 NP242 TRANSFER CASE 287
AX 15 MANUAL TRANSMISSION . . . . . . . . . . 32 TRANSMISSION/TRANSFER CASE
AX 4/5 MANUAL TRANSMISSION 1 SPECIFICATIONS 314
AX 4/5 MANUAL TRANSMISSION
INDEX
page page
Cleaning and Inspection 13 Transmission Assembly and Adjustment . . . . . . . 15
Gear Ratios .1 Transmission Disassembly and Overhaul .5
General Information 1 Transmission Identification 1
Recommended Lubricant 1 Transmission Installation 4
Service Diagnosis . . . , 1 Transmission Removal 3
Shift Pattern 1
GENERAL INFORMATION RECOMMENDED LUBRICANT

The AX 4 is a four speed manual transmission. The Recommended lubricant for AX 4/5 transmissions
AX 5 is a five speed manual transmission. Fifth gear is Mopar 75W-90, API Grade GL-5 gear lubricant, or
in the AX 5 is an overdrive range. The shift mecha equivalent SAE rated gear lubricant.
nism in both models is integral and mounted in the Correct lubricant fill level is to the bottom edge of
shift tower portion of the adapter housing (Fig. 1). the fill plug hole. The fill plug is at the passenger
The AX 4/5 is used for 2.5L engine applications. side of the adapter housing Fig. 4). The drain plug is
at the bottom of the case.
TRANSMISSION IDENTIFICATION Approximate dry fill lubricant capacity is 3.3 liters
The AX 4/5 identification code is on the bottom (3.5 qts.).
surface of the transmission case near the fill plug
(Fig. 2). The first number is year of manufacture. SERVICE DIAGNOSIS
The second and third numbers indicate month of
manufacture. The next series of numbers is the LOW LUBRICANT LEVEL
transmission serial number. A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an in
GEAR RATIOS correct lubricant level check.
AX 4 and AX 5 gear ratios are as follows: Leaks can occur at the mating surfaces of the gear
• First gear: 3.93:1 case, intermediate plate and adaptor or extension
• Second gear: 2.33:1 housing, or from the front/rear seals. A suspected
• Third gear: 1.45:1 leak could also be the result of an overfill condition.
• Fourth gear: 1.00:1 Leaks at the rear of the extension or adapter hous
• Fifth gear (AX 5): 0.85:1 ing will be from the housing oil seals. Leaks at com
• Reverse gear: 4.74:1 ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
SHIFT PATTERN tightening, or use of a non-recommended sealer.
The AX 4/5 first through fourth gear shift pattern A leak at the front of the transmission will be from
is in a conventional H configuration. On the AX 5, either the front bearing retainer or retainer seal. Lu
fifth gear is up and to the right and reverse gear is bricant may be seen dripping from the clutch hous-
down and to the right (Fig. 3).
21-2 AX 4/5 MANUAL TRANSMISSION J
J8921-1
Fig. 1 AX 4/5 Manual Transmission
© © 0 © ©
A A A A A
V V V V
© © © © © ©
I A X 51 J9021-12J
Fig. 3 Shift Pattern—AX 4/5 Transmission

I.D. CODE O N CASE
NEAR DRAIN PLUG A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda
J8921-2 tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
Fig. 2 Transmission Identification
ing after extended operation. If the leak is severe, it HARD SHIFTING
may also contaminate the clutch disc causing slip, Hard shifting is usually caused by a low lubricant
grab and chatter. level, improper or contaminated lubricants, compo
Transmissions filled from air or electrically pow nent damage, incorrect clutch adjustment, or by a
ered lubricant containers can be underfilled. This damaged clutch pressure plate or disc.
generally happens when the container delivery mech Substantial lubricant leaks can result in gear, shift
anism is improperly calibrated. Always check the lu rail, synchro and bearing damage. If a leak goes un
bricant level after filling to avoid an under fill detected for an extended period, the first indications
condition. of a problem are usually hard shifting and noise.
AX 4/5 MANUAL TRANSMISSION 21 - 3
J Worn or damaged synchro rings can cause gear
FILL PLUG
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings may
tend to stick slightly causing hard or noisy shifts. In
most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi
cient, improper, or contaminated lubricant can pro
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
J8921-4
TRANSMISSION REMOVAL
Fig. 4 Fill Plug Location (1) Shift transmission into first or third gear. Then
Incorrect or contaminated lubricants can also con raise vehicle on hoist.
tribute to hard shifting. The consequence of using (2) Support engine with adjustable jack stand. Be
non-recommended lubricants is noise, excessive wear, sure to position wood block between jack and oil pan.
internal bind and hard shifting. (3) Disconnect necessary exhaust system compo
Improper clutch release is a frequent cause of hard nents.
shifting. Incorrect adjustment or a worn, damaged (4) Disconnect rear cushion and bracket from
pressure plate or disc can cause incorrect release. If transmission (Fig. 5). Then remove skid plate, or
the clutch problem is advanced, gear clash during rear crossmember.
shifts can result.
(5) Disconnect transfer case shift linkage, vehicle (10) Disconnect vehicle speed sensor wires.
speed sensor wires, and vent hose. (11) Disconnect transmission and transfer case
(6) Disconnect clutch hydraulic lines. vent hoses.
(7) Disconnect transmission shift lever as follows: (12) Disconnect clutch master cylinder hydraulic
(a) Lower transmission-transfer case assembly line from concentric bearing inlet line (Fig. 8).
approximately 7-8 cm (3 in.) for access to shift le (13) Support transmission-transfer case assembly
ver. with a transmission jack. Secure assembly to jack
(b) Reach up and around transmission case and with safety chains.
unseat shift lever dust boot from transmission shift (14) Remove clutch housing brace rod on 4-cylinder
tower (Fig. 6). Move boot upward on shift lever for models.
access to retainer that secures lever in shift tower. (15) Remove clutch housing-to-engine bolts and re
(c) Reach up and around transmission case and move transmission-transfer case assembly.
press shift lever retainer downward with your fin (16) Remove bolts attaching transmission to trans
gers. Turn retainer counterclockwise to release it. fer case and separate components.
(d) Lift lever and retainer out of shift tower (Fig. (17) Remove concentric bearing and clutch housing
6). Do not remove the shift lever from the from transmission.
floorpan boots. Leave the lever in place for
later transmission installation.
Fig. 8 Hydraulic Line And Timing Sensor Location

TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 N*m (27 ft. lbs.) torque.
(2) Install concentric bearing. Secure bearing to
mounting pin with new retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis
sion input shaft splines with Mopar high tempera
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
(6) Install and tighten clutch housing-to-engine
bolts to 38 N*m (28 ft. lbs.) torque. Be sure the
housing is properly seated on engine block be
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear,
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down
Fig. 7 Marking Propeller Shaft And Axle Yokes ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Remove crankshaft position position sensor (9) Connect concentric bearing hydraulic line and
(Fig. 8). connect engine timing sensor wires.
J AX 4/5 MANUAL TRANSMISSION 21 - 5
(10) Remove jack from under transmission and TRANSMISSION DISASSEMBLY AND OVERHAUL
mount transfer case on jack.
(11) Align transfer case and transmission shafts ADAPTER HOUSING AND FRONT BEARING
and install transfer case. Tighten transfer case-to- RETAINER REMOVAL
transmission nuts/bolts to 35 N*m (26 ft. lbs.) torque. (1) Drain transmission lubricant.
(12) Remove jack stand from under engine and re (2) Remove concentric bearing.
position jack under transmission. Then remove trans (3) Remove clutch housing bolts and remove hous
mission jack. ing.
(13) Connect transfer case vent hose and shift link (4) On 2-wheel drive models, remove vehicle speed
age. Check and adjust linkage if necessary. sensor, speedometer adapter and speedometer driven
(14) Connect transmission and transfer case vent gear. Then remove extension housing seal (Fig. 9).
hoses.
SLIDE
(15) Connect backup light switch wires. HAMMER
(16) Connect vehicle speed sensor wires.
(17) Install and connect crankshaft position sensor
if equipped.
(18) Install rear crossmember, or skid plate (Fig.
5). On XJ, tighten crossmember-to-frame bolts to 41
N»m (31 ft. lbs.) torque. Then tighten transmission-
to-rear support bolts/nuts to 45 N-m (33 ft. lbs.)
torque. On YJ, tighten bolts/nuts to indicated torque
(Fig. 5).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 N-m (170 in.
lbs.) torque. 2WD
(20) On XJ, install skid plate, if removed. Tighten EXTENSION H O U S I N G
J9121-385
bolts to 42 N-m (31 ft. lbs.) torque. Tighten stud nuts
to 17 N-m (150 in. lbs.) torque. Fig. 9 Removing 2-Wheel Drive Extension Housing
(21) Top off transmission and transfer case lubri Seal
cant levels.
(22) Lower vehicle. (5) Remove detent spring and ball. Remove detent
plug (Fig. 10) and remove detent spring and ball
with pencil magnet.
REMOVE
Fig. 10 Detent Ball Plug Location

(6) Remove shift arm set bolt (Fig. 11) and remove
bolt and lockplate.
BEARING
RETAINER
SNAP
RING
J8921-13
Fig. 13 Removing Bearing Retainer Snap Ring

J8921-11
(11) Remove front bearing retainer and intermedi
Fig. 11 Set Bolt Removal ate plate by tapping them loose with plastic mallet
(Fig. 14).
(7) Remove shift lever shaft plug (Fig. 12). Then
pull shaft out with large magnet. INTERMEDIATE
PLATE
SHIFT LEVER
SHAFT
PLUG
FRONT
BEARING
RETAINER
J8921-14
J8921-12 Fig. 14 Removing Bearing Retainer And

Intermediate Plate
Fig. 12 Removing Shift Lever Shaft Plug
SHIFT MECHANISM DISASSEMBLY
(8) Remove adapter housing bolts. (1) Install two clutch housing bolts and spare
(9) Remove adapter housing by tapping it loose washers in intermediate plate (Fig. 15). Then clamp
with plastic mallet. plate and gear assembly in vise. Use enough wash
(10) Remove front bearing snap rings (Fig. 13). ers to prevent bolts from touching. Also be sure
vise jaws are clamped on bolt heads (Fig. 15).
INTERMEDIATE (2) Remove threaded plugs from intermediate

plate. Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 16).
(3) Remove shift fork pins with punch and hammer
(Fig. 17).
J8921-17
J8921-15
Fig. 15 Positioning intermediate Plate In Vise Fig. 17 Removing Shift Fork Pin
(4) Remove shift rail C-rings (Fig. 18).
Fig. 18 Shift Rail C-Ring Removal

(5) Pull No. 4 shift rail outward and remove lock
balls and pin (Fig. 19).
J8921-16 (6) Remove No. 4 shift rail, fifth gear and No. 3
shift fork (Fig. 20).
Fig. 16 Removing Lock Ball And Spring
21-8 AX 4/5 MANUAL TRANSMISSION
N O . 4 SHIFT RAIL
N O . 5 SHIFT
RAIL A N D SHIFT HEAD
J8921-21
LOCK
BALLS Fig. 21 Removing No. 5 Shift Rail And Shift Head
NO.3
J8921-19 SHIFT RAIL
Fig. 19 Removing No. 4 Shift Rail, Lock Balls And

Pin
FIFTH
GEAR
S H I R FORK
INTERLOCK
PINS
J8921-22
Fig. 22 Removing No. 3 Shift Rail And Interlock Pin
NO 1
S H I R RAIL
J8921-20
Fig. 20 Removing No. 4 Shift Rail And Fifth Gear

Shift Fork
(7) Pull No. 5 shift rail and shift head out of plate
(Fig. 21).
(8) Remove shift rail No.3. Catch interlock pins
as fail is removed (Fig. 22). I
(9) Remove No. 1 shift rail and interlock pin (Fig.
23).
J8921-23
Fig, 23 Removing No. 1 Shift Rail And Interlock Pin

(10) Remove shift rail No. 2 and shift forks 1 and 2 (12) Remove reverse shift arm and fork (Fig. 26).
(Fig. 24).
SHIFT F O R K S
N O . 1-2
NO.2
SHIFT RAIL
SHIFT
FORK
J8921-24
J8921-26
Fig. 24 Removing Shift Forks And No. 2 Shift Rail
(11) Remove reverse idler gear and shaft (Fig. 25). Fig. 26 Reverse Shift Arm Removal
MAINSHAFT DISASSEMBLY
(1) On AX 5 , measure fifth counter gear thrust
clearance with feeler gauge (Fig. 27). Clearance
should be 0.10 - 0.30 mm (0.004 - 0.012 in.).
COUNTER
FIFTH
GEAR
SNAP
RING
J8921-25
Fig. 25 Removing Reverse Idler Gear And Shaft C L E A R A N C E S H O U L D BE

0.004 T O 0.012 INCH
(0.10 T O 0.30 mm]
J9121-387
Fig. 27 Measuring Counter Fifth Gear Thrust

Clearance
21 - 1 0 AX 4 / 5 M A N U A L T R A N S M I S S I O N
(2) Engage two synchro sleeves to lock mainshaft (4) R e m o v e fifth spline gear, synchronizer and
gears (Fig. 28). counter fifth gear w i t h two-jaw puller (Fig. 30).
GEAR PULLER /FIFTH ^JJ ^COUNTER FIFTH

LOCK T H E S E
T W O SLEEVES
J892M062
Si
Fig. 30 Removing Fifth Gear Assembly

(5) R e m o v e spacer a n d r e m o v e lock ball with pen
cil m a g n e t (Fig. 31).
J8921-28
SPACER
Fig. 28 Locking Mainshaft Gears
(3) On A X 4, remove counter gear nut and oil
slinger. On A X 5, remove select fit snap ring that se
cures fifth spline gear and counter fifth gear on shaft
(Fig. 29). LOCK
BALL
PENCIL
MAGNET
FIFTH GEAR
SNAP RING
(SELECT FIT)
J8921-31
'J8921-1055 Fig, 31 Sp&c&r And Lock Bali Removal
Fig. 29 Removing Fifth Gear Snap Ring

(6) Remove reverse shift arm bracket (Fig. 32). (8) Remove rear bearing snap ring (Fig. 34).
REAR
BEARING
SNAP
RING
REVERSE
SHIFT
ARM
BRACKET
J8921-32 J8921-34
Fig. 32 Removing Reverse Shift Arm Bracket Fig. 34 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. 33). pull output shaft-counter gear assemblies out of plate
(Fig. 35).
INTERMEDIATE
INPUT-OUTPUT
PLATE SHAFT ASSEMBLY
REAR BEARING
RETAINER
RETAINER
BOLTS
C O U N T E R GEAR
[J8921-33 J8921-35
Fig. 33 Removing Rear Bearing Retainer Fig. 35 Removing Counter Gear And Output Shaft
(10) Remove rear bearing from intermediate plate.
(11) Remove input shaft and shaft roller bearings
from output shaft.
(12) Measure thrust clearance of output shaft
gears (Fig. 36). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.).
3RD
1ST 2ND
T H R U S T CLEARANCE
IS 0.004 T O 0.012 INCH
(0.10 T O 0 . 2 5 mm)
J8921-36
Fig. 36 Checking Output Shaft Gear Thrust
Clearance Fig. 38 Removing Fifth Gear And First Gear Rearing
And Race
(13) Remove output shaft fifth gear snap ring with
two screwdrivers (Fig. 37).
Fig. 39 Synchronizer Lock Ball Removal

Fig. 37 Removing Fifth Gear Snap Ring (19) Remove needle roller bearing from the shaft
(14) Press fifth gear, rear bearing, first gear and or second gear.
inner race off output shaft (Fig. 38). (20) Remove 3-4 synchronizer snap ring (Fig. 41).
(15) Remove needle roller bearing. (21) Press 3-4 synchronizer and third gear off shaft
(16) Remove synchronizer ring. (Fig. 42).
(17) Remove synchronizer lock ball with pencil (22) Remove needle roller bearing from shaft or
magnet (Fig. 39). gear.
(18) Press 1-2 synchronizer and second gear off
output shaft (Fig. 40).
Fig. 42 Removing 3-4 Synchronizer And Third Gear

Fig. 40 1-2 Synchronizer And Second Gear Removal
Check thickness of the output shaft and inner bear
ing race flanges with a micrometer or vernier cali
pers (Fig. 43). Minimum thickness for the shaft
flange is 4.8 mm (0.189 in.). Minimum thickness for
the bearing race flange is 3.99 mm (0.157 in.).
Fig. 41 Removing 3-4 Synchronizer Snap Ring

Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on
the bearings. This could cause severe damage to
the bearing roller and race surfaces.
Inspect the transmission case. Replace the case if
cracked, porous, or if any of the bearing and gear
bores are damaged. Fig. 43 Checking Flange Thickness
21 - 14 AX 4/5 MANUAL TRANSMISSION
Measure diameter of the output shaft journal sur

faces with a micrometer (Fig. 44). Second gear sur
face minimum diameter is 37.96 mm (1.495 in.).
Third gear surface minimum diameter is 34.98 mm
(1.377 in.). Replace the shaft if either of these sur
faces are worn beyond specified limits.
J8921-45
Fig. 45 Checking Output Shaft Runout
Fig. 44 Checking Shaft And Race Diameters

Measure output shaft runout with a dial indicator
(Fig. 45). Runout should not exceed 0.05 mm (0.002
in.).
Install the needle bearing and inner race in the
INNER RACE
first gear. Then check oil clearance between the gear J8921-46
and inner race (Fig. 46). Clearance should be 0.009 -
0.032 mm (0.0004 - 0.0013 in.). Fig. 46 Checking Gear-To-Race Clearance
J AX 4/5 MANUAL TRANSMISSION 21-15
Install the needle bearings and the second, third Check shift fork-to-synchronizer hub clearance
and counter fifth gears on the output shaft. Check oil with a feeler gauge (Fig. 49). Replace the fork if
clearance between the gears and shaft with a dial in clearance exceeds 1.0 mm (0.039 in.).
dicator (Fig. 47).
Oil clearance for all three gears is 0.009 - 0.0013
mm (0.0004 - 0.0013 in.).
J8921-49
Fig. 49 Checking Fork-To-Hub Clearance

TRANSMISSION ASSEMBLY AND ADJUSTMENT
Lubricate the transmission components with Mopar
Fig. 47 Checking Gear-To-Shaft Clearance
75W-90, GL 5 gear lubricant during assembly. Use
Check synchronizer ring wear (Fig. 48). Insert each petroleum jelly to lubricate seal lips and/or hold
ring in matching gear. Measure clearance between parts in place during installation. Refer to the
each ring and gear with feeler gauge. Replace ring if Counter Gear Comparison Chart (Fig. 104) during
clearance exceeds 2.0 mm (0.078 in.). assembly for AX 4/5 gear differences.
ASSEMBLING OUTPUT SHAFT, INPUT SHAFT
AND COUNTER GEAR
(1) If front bearing was removed from input shaft,
press new bearing on shaft (Fig. 50).
(2) Secure front bearing with thickest snap ring
that will fit in groove (Fig. 50).
(3) Press front bearing on counter gear. Secure
bearing with thickest snap ring that will fit in ring
groove (Fig. 51).
Fig. 48 Checking Synchronizer Ring Wear

COUNTER GEAR
F R O N T
cci err e r r
SELECT-FIT REARING
B E A R I N O
SNAP RING
I.D. Mark Snap l i n g Thickness mm (in.)

1 2.05-2.10(0.0807-0.0827
2 2.10-2.15 (0.0827-0.0846
3 2.15-2.20 (0.0846-0.0866
4 2.20-2.25 (0.0866-0.0886
5 2.25-2.30 (0.0886-0.0906
6 2.30-2.35 (0.0906-0.0925
J8921-51
Fig. 51 Installing Counter Gear Front Bearing And

Snap Ring
and adapter (Fig. 52). Bearing retainer seal depth is
11.2 - 12.1 mm (0.441 - 0.480 in.).
FRONT
BEARING
RETAINER
I.D. M a r k Snap Ring Thickness mm (in.)

0 2.05-2.10 0.0807-0.0827
1 2.10-2.15 0.0827-0.0846 SEAL
2 2.15-2.20 0.0846-0.0866 INSTALLER | Kg?
3 2.20-2.25 0.0866-0.0886
4 2.25-2.30 0.0886-0.0906 J8921-52
5 2.30-2.35 0.0906-0.0925
J8921-50 Fig. 52 Oil Seal Installation

Fig. 50 Installing Front Bearing And Snap Ring (5) Install reverse shaft and shaft retaining pin in
adapter. Then install access hole plug with torx bit
(4) Install new oil seals in front bearing retainer
(Fig. 53).
(8) Assemble and install third gear, needle bear

ing, synchronizer ring, 3-4 synchronizer and snap
ring on output shaft (Fig. 55). Use thickest snap ring
that fits in shaft groove.
REVERSE
SHAFT
RETAINING
PIN
ACCESS
PLUG
I.D. M a r k Snap Ring Thickness m m (in.)

C-1 1.75-1.80 0.0689-0.0709 i
J8921-53 D 1.80-1.85 0.0709-0.0728 •
D-1 1.85-1.90 0.0728-0.0748
E 1.90-1.95 0.0748-0.0768
Fig. 53 Installing Reverse Shaft Pin E-1 1.95-2.00 0.0768-0.0787
F 2.00-2.05 0.0788-0.0807
(6) Lubricate transmission components with speci F-l 2.05-2.10 0.0807-0.0827
fied gear lubricant.
J8921-55
(7) Assemble 1-2 and 3-4 synchronizer hubs,
sleeves, springs and key inserts (Fig. 54). Fig. 55 Installing Third Gear And 3-4 Synchronizer
SLEEVES (9) Verify third gear thrust clearance with feeler
gauge (Fig. 56). Clearance should be 0.10 - 0.25 mm
(0.004 - 0.010 in.).
FEELER THIRD
GAUGE GEAR
FRONT
1-2 3-4
SYNCHRONIZER SYNCHRONIZER
ASSEMBLY ASSEMBLY
J8921-54 J8921-56
Fig. 54 Synchronizer Identification Fig. 56 Checking Third Gear Clearance

21 - 18 AX 4/5 MANUAL TRANSMISSION J
(10) Assemble second gear, gear needle bearing, (12) Assemble first gear, synchronizer ring, gear
synchronizer ring and 1-2 synchronizer. Then press needle bearing and inner race (Fig. 59). Then install
assembly on output shaft (Fig. 57). assembly on output shaft. Rotate inner race until
aligned with locking ball.
(13) Press rear bearing on shaft (Fig. 59). Snap
ring groove in bearing goes toward rear. Use screw
driver to hold inner race in position when installing
bearing (Fig. 60).
(14) Install snap ring on rear bearing.
FIRST
GEAR
LOCK
REAR BEARING BALL NEEDLE BEARING
I N N E R RACE FIRST
GEAR
Fig. 57 installing Second Gear And Synchronizer J8921-59
(11) Install first gear lock ball in output shaft (Fig. Fig. 59 First Gear Assembly
58).
Fig. 60 Installing Output Shaft Rear Bearing

Fig. 58 Installing First Gear And Lock Ball
4 AX 4/5 MANUAL TRANSMISSION 21-19
(15) Check first-second gear thrust clearance (Fig.

61). Standard clearance is 0.10 - 0.25 mm (0.004 -
0.010 in.).
SELECT
FIFTH
GEAR
SNAP
RING.
S T A N D A R D CLEARANCE
0.004-0.010 INCH
(0.10-0.25 mm)
J8921-61
Fig. 61 Checking First-Second Gear Clearance

(16) Press fifth gear on output shaft (Fig. 62).
FIFTH
GEAR
I.D. M a r k S n a p R i n g T h i c k n e s s m m (in.)
Fig. 62 Installing Output Shaft Fifth Gear
A 2.67-2.72 (0.1051-0.1071)
(17) Install fifth gear snap ring (Fig. 63). Use B 2.73-2.78 0.1075-0.1094)
thickest snap ring that will fit in shaft groove. C 2.79-2.84 0.1098-0.1118)
D 2.85-2.90 (0.1122-0.1142
E 2.91-2.96 (0.1146-0.1165)
F 2.97-3.02 (0.1169-0.1189)
G 3.03-3.08 (0.1193-0.1213)
H 3.09-3.14 (0.1217-0.1236)
J 3.15-3.20 (0.1240-0.1260
K 3.21-3.26 (0.1264-0.1283
L 3.27-3.32 (0.1287-0.1307)
J8921-63
Fig. 63 Selecting/Installing Fifth Gear Snap Ring

(18) Lubricate input shaft roller bearings with pe

troleum jelly and install rollers in shaft (Fig. 64).
INPUT
SHAFT
J8921-64
Fig. 66 Installing Counter Gear
Fig. 64 installing Input Shaft Bearing Rollers
(19) Install output shaft assembly in intermediate
plate (Fig. 65). Tap plate with mallet and pull on
shaft to seat assembly.
INTERMEDIATE
PLATE
Fig. 65 installing Output Shaft In Intermediate Plate

(20) Install input shaft on output shaft.
(21) Install counter gear in intermediate plate J8921-67
(Fig. 66).
Fig. 67 Installing Bearing Retainer And Snap Ring
(22) Install rear bearing snap ring and install
bearing retainer (Fig. 67). Tighten retainer screws to (24) Install lock ball, spacer and needle bearing
18 N*m (13 ft. lbs.) torque. (Fig. 69) on counter shaft.
(23) Install reverse shift arm (Fig. 68). Tighten at (25) On AX 5, assemble counter fifth gear and syn
taching bolt to 18 N T H (13 ft. lbs.) torque. chro components (Figs. 69 and 104).
J
Fig. 70 Fifth Gear And Synchronizer

Installation—AX 5
SPLINE
GEAR
Fig. 68 Installing Reverse Shift Fork

SNAP
RING
Fig. 71 Installing Fifth Gear-AX 5
COUNTER
FIFTH
GEAR
J9121-390
Fig. 69 Counter Fifth Gear And Synchronizer

Assembly—AX 5
(26) On AX 5, install assembled gear and synchro
nizer on counter shaft (Fig. 70).
(27) Install remaining synchronizer ring and spline
fifth gear (Fig. 71). Use length of pipe to tap gear
into place.
(28) Shift 1-2 and 3-4 synchronizer sleeves into
gear to lock output shaft and counter gear (Fig. 28).
(29) On AX 4, install oil slinger and lock nut on
counter gear (Fig. 104).
(30) On AX 5, install fifth gear snap ring (Fig. 72).
Fig. 72 Fifth Gear Thrust Clearance—AX 5
(31) Disengage 1-2 and 3-4 synchronizer sleeves. mm (0.004 - 0.010 in.). Adjust clearance with differ-
(32) On AX 5, check counter fifth gear thrust ent thickness snap ring if necessary,
clearance (Fig. 72). Standard clearance is 0.10 - 0.30
© REVERSE FORK A N D SHIFT ARM

© SHAFT PLUG
® 1-2 SHIFT FORK

© REVERSE P I N
CD 3-4 SHIFT FORK

© RETAINING P I N A N D PLUG
® LOCK BALL, SPRING A N D PLUG (AX 5)

© NO. 5 SHIFT RAIL
CD BRACKET BOLT
© INTERLOCK P I N
© N O . 3 SHIFT RAIL
© INTERLOCK PIN
® N O . 1 SHIFT RAIL
© INTERLOCK P I N
® C-RING C-RING
® N O . 2 SHIFT RAIL
© INTERLOCK PIN
© C-RING
© FIFTH-REVERSE FORK (AX 5)
© LOCK BALL, SPRING A N D PLUG

© REVERSE SHIFT HEAD
© SHIFT A R M
© LOCK BALLS (AX 5)
NO. 4 SHIFT RAIL (AX 5)
© S E T BOLT A N D LOCK PLATE
®
© SHIFT LEVER SHAFT
© REVERSE A R M BRACKET
J9021-122
Fig. 73 Shift Components
J
SHIFT MECHANISM ASSEMBLY AND (3) Install 1-2 and 3-4 shift forks in synchronizer
INSTALLATION sleeves. Then slide No. 2 shift rail through interme
When assembling the shift mechanism, refer to diate plate and into forks (Fig. 76).
Figure 73 for component details and location. 1-2
(1) Install reverse shift arm. Then seat shift fork
in bracket (Fig. 74).
J8921-76
Fig. 76 installing No. 2 Shift Rail and Shift Forks

(4) Coat shift rail interlock pins and balls with lib
eral quantity petroleum jelly to hold them in place.
(5) Refer to Figure 77 for interlock ball and pin po
sitions during following assembly steps.
Fig. 74 Installing Reverse Shift Arm

(2) Install reverse idler gear on shaft. Then install
shaft and gear in intermediate plate (Fig. 75). Install
shaft lock plate and tighten attaching bolt to 18 N*m
Fig. 75 Installing Reverse Idler Gear And Shaft

J902M23
Fig. 77 Interlock Ball And Pin Position

(6) Insert first interlock pin in intermediate plate (8) Slide No. 1 rail through 1-2 shift fork (Fig. 80).
(Fig. 78). Use pencil magnet and screwdriver to in
stall pin.
INTERLOCK PIN
PENCIL
MAGNET
J8921-80
INTERMEDIATE
PLATE J8921-78
Fig. 80 Installing No. 1 Shift Rail
Fig. 78 Installing First Interlock Pin (9) Install largest interlock pin between Nos. 1 and
(7) Install smaller diameter interlock pin in No. 1 3 shift rails (Fig. 81).
rail (Fig. 7 9 ) .
NO. 1
SHIR
1-3 RAIL
RAIL
INTERLOCK
PIN
INTERLOCK
PIN PENCIL
MAGNET
J8921-81
J8921-79
Fig. 81 Installing 1-3 Shift Rail Interlock Pin
Fig. 79 Installing Interlock Pin In No. i Shift Rail
21 - 28 AX 4 / 1 MANUAL TRANSMISSION J
(10) Install interlock pin in No. 3 shift rail (Fig. (12) Assemble reverse shift head and No. 5 shift
82). rail.
(13) Install No. 5 shift rail in intermediate plate
and engage shift head on No. 3 shift rail (Fig. 8 4 ) .
REVERSE
SHIFT
NO.3 HEAD
SHIFT
RAIL
NO.5
RAIL
J9121-393
Fig. 82 installing No. 3 Shift Rail Interlock Pin

(11) Slide No. 3 rail into reverse shift head (Fig.
83).
NO.3
RAIL
J8921-84
Fig. 84 Installing Reverse Shift Head

(14) Install reverse shift head lock ball with screw
driver and pencil magnet (Fig. 8 5 ) .
REVERSE
SHIFT
HEAD
LOCK
BALL
J8921-83
Fig. 83 Installing No. 3 Shift Rail
J8921-85
Fig. 85 Installing Reverse Shift Head Lock Ball

J AX 4/5 MANUAL TRANSMISSION 21 - 2 7
(15) Shift fifth gear synchronizer sleeve rearward (17) Install shift rail lock ball with pencil magnet
to lock it (Fig. 86). and screwdriver (Fig. 88).
SYNCHRONIZER
SLEEVE J9121-391
Fig. 86 Locking Fifth Synchronizer

(16) On AX 5, install fifth-reverse shift fork in
synchronizer sleeve, Then slide No. 4 shift rail into
fork (Fig. 87).
J8921-88
REVERSE
SHIR Fig. 88 Lock Bali Installation
HEAD
(18) Check interlock operation as follows: Move
No. 1 shift rail rearward to first gear position. Inter
lock operation is OK if remaining shift rails did not
move.
(19) Install new shift fork pins (Fig. 89).
FORKS
J9121-392
Fig. 87 Fifth-Reverse Shift Fork Installation
J8921-89
Fig. 89 Installing Shift Fork Pins

21 - 28 AX 4/1 MANUAL TRANSMISSION — • J
(20) Install new shift rail Orings (Fig. 90). 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. 92).
INTERMEDIATE
Fig. 90 Installing Shift Rail C-Rings

(21) Apply sealer to threads of lock ball plugs. J8921-92
(22) Install lock balls and springs in intermediate
plate. Short spring goes in top hole of intermedi Fig. 92 Installing Transmission Case
ate plate. (4) Install new front bearing snap ring (Fig. 93).
(23) Install lock ball and spring plugs (Fig. 91).
Tighten plugs to 19 N*m (14 ft. lbs.) torque.
J8921-91
Fig. 91 Installing Lock Ball Plugs

Fig. 93 Installing Front Bearing Snap Ring
J (5) Install new gasket on front bearing retainer (8) Install shift arm lock plate with pliers (Fig.
and install retainer on case (Fig. 94). 96). Then install and tighten lock plate set bolt to 38
Fig. 94 Installing Front Bearing Retainer Fig. 96 Shift Arm Lock Plate Installation
(6) Install adapter or extension housing on inter (9) Install and tighten shaft plug to 18 N*m (13 ft.
mediate plate (Fig. 95). Tighten housing bolts to 37 lbs.) torque (Fig. 97).
(7) Install shift arm (Fig. 95).
Fig. 95 Installing Adapter Housing And Shift Arm Fig. 97 Shaft Plug Installation
(10) Install lock ball and spring in housing. Then (12) Install shift tower and new gasket on housing
apply sealer to ball plug and install plug (Fig. 98). (Fig. 100). Tighten tower bolts to 18 N-m (13 ft. lbs.)
Tighten plug to 19 N-m (14 ft. lbs.) torque. torque.
(13) Install backup lamp switch (Fig. 100). Tighten
switch to 37 N-m (27 ft. lbs.) torque.
BACKUP
LAMP
SHIFT SWITCH
TOWER
PLUG
J8921-98
Fig. 98 installing Ball Plug J8921-100
(11) Install reverse pins in housing (Fig. 99).

Fig. 100 Installing Shift Tower And Backup Lamp
Tighten pins to 27 N-m (20 ft. lbs.) torque.
Switch
REVERSE
PIN
(14) On 2-wheel drive models, install new seal in
extension housing (Fig. 101).
EXTENSION HOUSING SEAL
HOUSING SEAL INSTALLER
TOOL
J9121-386
J8921-99
Fig. 101 Extension Housing Seal Installation—2WD
Fig. 99 Install Reverse Pins Models
SEAL ADAPTER SPEEDOMETER

RETAINER ADAPTER
O-RING DRIVEN
GEAR
DISTANCE
SENSOR SPEEDOMETER ADAPTER 1 0 1 0 1O T O NUMBER ALIGN N U M B E R
ADAPTER CLAMP J 9 1 2 1
^ SETS SET W I T H
INDEX MARK
Fig. 102 Speedometer Components O N HOUSING
(15) On 2-wheel drive models, install speedometer J8921-103

driven gear, adapter and distance sensor as follows: Fig. 103 Indexing Speedometer Adapter
(a) Assemble adapter and gear (Fig. 102).
(b) Count number of teeth on speedometer driven (d) Rotate adapter until desired number set
aligns with index mark on extension housing (Fig.
gear.
103).
(c) Locate number sets on adapter face that cor
(e) Install and tighten adapter retainer bolt to 11
respond to number of teeth on driven gear (Fig.
103).
(f) Install distance sensor on adapter (Fig. 102).
(16) Install clutch housing and concentric bearing.
SNAP FIFTH
RING' "GEAR (AX 5)
COUNTER
GEAR
5TH
SPLINE
fGEAR
SYNCHRO
RING SYNCHRO
HUB/SLEEVE
J9121-394
Fig. 104 Counter Gear Components

21-32 AX 15 MANUAL TRANSMISSION J
AX 15 MANUAL TRANSMISSION
INDEX
page page
General Information 32 Transmission Installation—AX 15 35
Service Diagnosis 33 Transmission Lubricant 32
Transmission Assembly and Adjustment 51 Transmission Removal—AX 15 34
Transmission Disassembly and Overhaul . . . . . . . 36 Transmission Shift Pattern . . . . . . . . . . . . . . . . . . 32
Transmission Gear Ratios 33 Transmission Switch and Plug Locations 33
Transmission Identification 32
GENERAL INFORMATION TRANSMISSION SHIFT PATTERN

The AX 15 is a 5-speed, synchromesh, manual The AX 15 shift pattern is shown in Figure 3. First
transmission. Fifth gear is an overdrive range with a and second and third and fourth gear ranges are in
ratio of 0.79:1. The shift mechanism is integral and line for improved shifting. Fifth and reverse gear
mounted in the shift tower portion of the adapter ranges are also in line at the extreme right of the
housing (Fig. 1). pattern (Fig. 3).
An adapter housing is used to attach the transmis The AX 15 is equipped with a reverse lockout
sion to the transfer case on 4-wheel drive models. A
mechanism. The shift lever must be moved through
standard extension housing is used on 2-wheel drive
models. the Neutral detent before making a shift to reverse.
The AX 15 is used in XJ and YJ models with a
4.0L engine. The AX 15 is designed for use with ei TRANSMISSION LUBRICANT
ther two-wheel drive or four-wheel drive applica Recommended lubricant for AX 15 transmissions is
tions. Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
TRANSMISSION IDENTIFICATION Correct lubricant refill or top-off level is to the bot
The AX 15 identification code numbers are on the tom edge of the fill plug hole.
bottom surface of the transmission gear case (Fig. 2). Lubricant capacity is:
The first number is year of manufacture. The sec • 3.10 liters (3.27 qts.) in 4-wheel drive models.
ond and third numbers indicate month of manufac • 3.15 liters (3.32 qts.) in 2-wheel drive models.
ture. The next series of numbers is the transmission
serial number.
1 t
J8921-1023
Fig. 1 AX 15 Manual Transmission

J AX 15 MANUAL TRANSMISSION 21 - 3 3
GEAR
CASE
BACKUP
LIGHT
SWITCH
I.D. CODE
J8921-1024
LOCATION
Fig. 2 Identification Code Number Location Fig. 5 Drain Plug And Backup Light Switch Location
© ® © TRANSMISSION GEAR RATIOS

The transmission gear ratios are as follows:
First gear - 3.83:1
Second gear - 2.33:1
Third gear - 1.44:1
Fourth gear - 1.00:1
Fifth gear - 0.79:1
Reverse - 4.22:1
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL

® © ® A low transmission lubricant level is generally the
J8921-1025 result of a leak, inadequate lubricant fill, or an in
correct lubricant level check.
Fig. 3 AX 15 Shift Pattern
Leaks can occur at the mating surfaces of the gear
TRANSMISSION SWITCH AND PLUG LOCATIONS case, intermediate plate and adapter or extension
The fill plug is at the driver side of the gear case housing, or from the front/rear seals. A suspected
(Fig. 4). leak could also be the result of an overfill condition.
The drain plug and backup light switch are on the Leaks at the rear of the extension or adapter hous
passenger side of the gear case (Fig. 5). ing will be from the housing oil seals. Leaks at com
GEAR CASE ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu
bricant may be seen dripping from the clutch hous
ing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip,
grab and chatter.
Transmissions filled from air or electrically pow
ered lubricant containers can be underfilled. This
generally happens when the container delivery mech
anism is improperly calibrated. Always check the lu
bricant level after filling to avoid an under fill
condition.
Fig. 4 Fill Plug Location A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda TRANSMISSION NOISE

tions will ensure an accurate check and avoid an un- Most manual transmissions make some noise dur
der-or-overfill condition. ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
HARD SHIFTING speeds.
Hard shifting is usually caused by a low lubricant Severe, obviously audible transmission noise is
level, improper or contaminated lubricants, compo generally the result of a lubricant problem. Insuffi
nent damage, incorrect clutch adjustment, or by a cient, improper, or contaminated lubricant can pro
damaged clutch pressure plate or disc. mote rapid wear of gears, synchros, shift rails, forks
Substantial lubricant leaks can result in gear, shift and bearings. The overheating caused by a lubricant
rail, synchro and bearing damage. If a leak goes un problem, can also lead to gear breakage.
detected for an extended period, the first indications
of a problem are usually hard shifting and noise. TRANSMISSION R E M O V A L - A X 15
Incorrect or contaminated lubricants can also con (1) Shift transmission into first or third gear.
tribute to hard shifting. The consequence of using (2) Raise vehicle on a hoist.
non-recommended lubricants is noise, excessive wear, (3) Disconnect necessary exhaust system compo
internal bind and hard shifting. nents.
Improper clutch release is a frequent cause of hard (4) Support transmission with adjustable jack
shifting. Incorrect adjustment or a worn, damaged stand.
pressure plate or disc can cause incorrect release. If (5) Disconnect rear cushion and mounting bracket
the clutch problem is advanced, gear clash during from transmission, or transfer case (Fig. 1).
shifts can result. (6) On XJ, remove rear crossmember. On YJ, re
Worn or damaged synchro rings can cause gear move skid plate (Fig. 1).
clash when shifting into any forward gear. In some (7) Disconnect transmission shift linkage, speed
new or rebuilt transmissions, new synchro rings may ometer cable, transfer case vacuum lines and clutch
tend to stick slightly causing hard or noisy shifts. In hydraulic lines.
most cases, this condition will decline as the rings (8) Lower transmission-transfer case assembly no
wear-in. more than 7.6 cm (3 in.) for access to shift lever.
W I T H 4.0L ITEM TORQUE
ENGINE A 4 1 - 6 8 N-m (30-50 ft. lbs.)
B 2 7 - 4 7 N-m (20-35 ft. lbs.)
MOUNTING
W I T H 2.5L
BRACKET
ENGINE
INSULATORS^
WASHER •
CUSHION
SKID
PLATE
J9321-261
Fig. 1 Rear Mount Components (YJ Shown)

J AX 15 MANUAL TRANSMISSION 21 - 35
(9) Reach up and around transmission case and

unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2). It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in place
for later installation.
Fig. 4 Timing Sensor And Clutch Hydraulic Line

Location
(15) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(16) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(17) Remove clutch housing brace rod.
(18) Remove clutch housing-to-engine bolts and re
move transmission-transfer case assembly.
(19) Remove bolts attaching transmission to trans
fer case and separate components.
(20) Remove concentric bearing and clutch housing
from transmission. Secure bearing nylon straps to
hold bearing piston in place.
TRANSMISSION INSTALLATION-AX 15
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 N*m (27 ft-lbs) torque.
(2) Install concentric bearing. Secure bearing to
mounting pin with new retainer clip.
(3) Mount transmission on transmission jack. Se
cure transmission with safety chains.
(4) Lightly lubricate pilot bearing and transmis
sion input shaft splines with Mopar high tempera
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
(6) Install and tighten clutch housing-to-engine
Fig. 3 Marking Propeller Shaft And Axle Yoke bolts to 38 N-m (28 ft. lbs.) torque. Be sure housing
is properly seated on engine before tightening
(11) Mark front and rear propeller shafts for in bolts.
stallation alignment (Fig. 2). Then remove both (7) Lower transmission no more than 7.6 cm (3 in.)
shafts. for access to the shift tower.
(12) Remove engine timing sensor (Fig. 4). (8) Reach up and around the transmission and in
(13) Disconnect transmission and transfer case sert shift lever in shift tower. Press lever retainer
vent hoses. downward and turn it clockwise to lock it in place.
(14) Disconnect clutch master cylinder hydraulic Then install lever dust boot on shift tower.
line from concentric bearing inlet line (Fig. 4). (9) Connect concentric bearing hydraulic line and
engine timing sensor.
(10) Remove jack from under transmission and (3) Remove shift tower bolts and remove tower
mount transfer case on jack. from adapter or extension housing (Fig. 2).
(11) Align transfer case and transmission shafts (4) Remove gasket from shift tower (Fig. 3).
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 N«m (26 ft. lbs.) torque.
(12) Move jack stand from under engine and repo
sition it under transmission. Then remove transmis
sion jack.
(13) Connect transfer case vacuum hoses and link
age. Check and adjust linkage if necessary.
(14) Connect transmission and transfer case vent
hoses.
(15) Connect backup light switch wires.
(16) Connect vehicle speed sensor and wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 N»m (30 ft. lbs.) torque. Tighten transmis
sion-to-rear cushion and bracket bolts/nuts to 45 N«m
(18) On YJ, install rear cushion and bracket and Fig. 2 Shift Tower Removal/Installation
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
.SHIFT
(19) Align and install front/rear propeller shafts.
TOWER
Tighten shaft U-joint clamp bolts to 19 N«m (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nnn (31 ft. lbs.) torque. Tighten stud nuts
#
to 17 N m (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL

ADAPTER/EXTENSION HOUSING REMOVAL -1033
(1) Remove hydraulic concentric bearing, clutch
housing and shift lever if not previously removed. Fig. 3 Shift Tower Gasket Removal/Installation
(2) On 2-wheel drive models, remove extension (5) Remove shift arm retainer bolt (Fig. 4).
housing seal (Fig. 1). (6) Loosen and remove restrictor pins (Fig. 5).
SLIDE
HAMMER
EXTENSION H O U S I N G
J9121-385
Fig. 1 Removing Extension Housing Seal

Fig. 4 Shift Arm Retainer Bolt Removal/Installation
SHIFT
ARM
J8921-1038
Fig. 5 Removing/installing Restrictor Pins Fig. 8 Shift Arm Removal/Installation

(7) Remove shift arm shaft plug (Fig. 6). (10) Remove plug for reverse shift head lock ball.
(8) Remove shift arm shaft with large magnet (Fig. Plug is at right side of adapter housing near backup
7). light switch (Fig. 9).
(9) Remove shift arm (Fig. 8). (11) Remove lock ball spring with pencil magnet
(Fig. 10).
(12) Remove shift head lock ball with pencil mag
net (Fig. 11).
Fig. 6 Removing/Installing Shift Lever Shaft Plug
Fig. 9 Removing/Installing Lock Ball Plug
Fig. 7 Removing/Installing Shift Lever Shaft

Fig. 10 Removing/Installing Lock Ball Spring
Fig. 11 Removing/Installing Shift Head Lock Ball

(13) Remove backup light switch from adapter/ex
tension housing.
(14) On 2-wheel drive models, remove distance
sensor, speedometer adapter and driven gear if not
removed previously.
(15) Remove adapter/extension housing bolts (Fig.
12).
(16) Loosen adapter/extension housing with rubber
mallet (Fig. 13).
(17) Remove housing after loosening it (Fig. 14)
(18) Remove adapter housing oil seal with pry tool
(Fig. 15).
Fig. 12 Adapter Housing Bolt Locations

Fig. 13 Loosening Adapter Housing Fig. 16 Front Bearing Retainer Removal
Fig. 14 Adapter Housing Removal Fig. 17 Front Bearing Retainer Seal Location
(4) Remove cluster gear front bearing snap ring
(Fig. 19).
Fig. 15 Removing Adapter Housing Seal

GEAR CASE REMOVAL
(1) Remove bearing retainer bolts and remove re Fig. 18 Removing Input Shaft Bearing Snap Ring
tainer (Fig. 16). (5) Loosen gear case by tapping it away from inter
(2) Remove retainer oil seal with pry tool (Fig. 17). mediate plate with rubber mallet (Fig. 20).
(3) Remove input shaft bearing snap ring (Fig. 18).
21 - 40 AX 15 MANUAL TRANSMISSION J
FIFTH GEAR AND SYNCHRO ASSEMBLY
REMOVAL
(1) Remove three lock ball plugs from intermediate
plate (Fig. 22).
SNAP
RING
PLIERS
CLUSTER
GEAR F R O N T
BEARING
SNAP
RING
J8921-1049 INTERMEDIATE
PLATE
Fig. 19 Removing Cluster Gear Front Rearing Snap
Ring
(6) Remove gear case from geartrain and interme
Op J892I-1Q52
diate plate (Fig. 21).
(7) On 2-wheel drive models, remove speedometer Fig. 22 Lock Ball Plug Locations
gear snap ring and remove speedometer gear and
spacer from output shaft. (2) Remove three lock ball springs and lock balls
from intermediate plate with pencil magnet (Fig. 23).
INTERMEDIATE RUBBER
PLATE MALLET
GEAR
CASE
J8921-1050
Fig. 20 Loosening Gear Case

GEAR INTERMEDIATE
CASE PLATE
J8^1-1G5T
Fig. 23 Removing/installing Lock Ball And Spring
J8921-1051
Fig. 21 Gear Case Removal

AX 15 MANUAL TRANSMISSION 21 - 41
INTERMEDIATE
PLATE
VISE
JAWS
BOLTS
AND
WASHERS
J8921-1054
Fig. 24 Mounting intermediate Plate And Geartrain in Vise

(3) Mount intermediate plate and geartrain assem (5) Remove E-ring that secures reverse shift arm
bly in vise as follows: to fork (Fig. 26).
(a) Insert two spare bolts in one bottom bolt hole REVERSE
in intermediate plate. Insert bolts from opposite SHIFT ARM
sides of plates (Fig. 24). BRACKET
(b) Install enough flat washers under each bolt

head to prevent bolts from touching (Fig. 24).
(c) Tape bolts and washers in place and mount
intermediate plate in vise (Fig. 24). E-RING
(d) Clamp vise jaws securely against bolt heads
(Fig. 24). Do not clamp vise jaws on intermedi
ate plate. Clamp only on bolt heads. REVERSE
SHIFT ARM
(4) Remove fifth gear snap ring (Fig. 25). Retain
snap ring for assembly reference. I t is a select fit
component.
J8921-1056
Fig. 26 Removing Reverse Shift Arm E-Ring

(6) Remove bolts attaching reverse shift arm
bracket to intermediate plate. Then remove bracket
(Fig. 27).
FIFTH GEAR
S N A P RING (7) Remove reverse shift arm and shoe (Fig. 28).
(SELECT FIT)
J8921-1055
Fig. 25 Fifth Gear Snap Ring Removal

21-42 AX 15 MANUAL TRANSMISSION ^ — — J
Fig. 28 Removing Reverse Shift Arm And Shoe

(8) Remove fifth gear shift fork set screw (Fig. 29).
(9) Move fifth gear shift rail forward until it clears Fig. 31 Removing Reverse Shift Head And Rail
shift fork.
(12) Measure thrust clearance between counter
(10) Remove fifth gear shift fork from synchro
fifth gear and thrust ring with feeler gauge. Clear
sleeve (Fig. 30). ance should be 0.10 - 0.40 mm (0.003 - 0.019 in.). If
clearance exceeds limits, gear and/or ring will have
to be replaced.
(13) Loosen fifth spline gear with standard two-jaw
puller (Fig. 32). Position puller jaws behind fifth
counter gear as shown.
(14) Remove fifth spline gear (Fig. 33).
(15) Remove fifth gear synchro ring (Fig. 34).
(16) Remove fifth gear synchro and sleeve assem
bly (Fig. 35),
Fig. 29 Removing Fifth Gear Fork Set Screw

J AX 1 5 MANUAL TRANSMISSION 21 - 43
Fig. 32 Loosening Fifth Spline Gear Fig. 35 Removing Counter Fifth Gear And Synchro
Assembly
Fig. 33 Removing Fifth Spline Gear

Fig. 36 Removing Fifth Gear Thrust Ring
Fig. 34 Removing Fifth Gear Synchro Ring

(17) Remove counter fifth gear thrust ring (Fig. Fig. 37 Removing Thrust Ring Lock Rail
36). (19) Remove bolts attaching output shaft rear
(18) Remove thrust ring lock ball with pencil mag bearing retainer to intermediate plate (Fig. 38).
net (Fig. 37). (20) Remove rear bearing retainer (Fig. 39).
(21) Remove reverse gear and shaft (Fig. 40).
BEARING REVERSE IDLER Z 3 REVERSE

RETAINER BEARING IDLER
GEAR
RETAINER SHAFT
BOLTS
SOCKET
A N D EXTENSION \ J8921-1068 JS921-1070
Fig. 38 Removing Output Shaft Rear Bearing Fig. 40 Removing Reverse Idler Gear And Shaft
Retainer Bolts
SHIFT RAIL AND FORK REMOVAL
OUTPUT SHAFT There are a total of five shift rails in the AX 15
REAR BEARING
RETAINER transmission. The 1-2, 3-4, fifth gear and front re
verse shift rails are shown in Figure 41.
Two shift rails are used for reverse gear range. The
front reverse rail is at the forward side of the inter
mediate plate (Fig. 41). The short rear reverse rail
and reverse shift head are at the rear side of the in
termediate plate.
It is not necessary to remove the shift rails if
they do not require service during overhaul.
Only the shift forks need be removed for acpess
to the transmission shafts and gears.
(1) Remove fifth gear shift rail (Fig. 41). Catch
lock ball in your hand as rail comes out of interme
diate plate.
Fig. 39 Removing Output Shaft Rear Bearing (2) Remove 1-2 and 3-4 shift rail C-rings with two
Retainer screwdrivers of equal size and length (Fig. 42).
3-4
S H I F T FORK
REVERSE S H I F T
RAIL (FRONT)
FIFTH
GEAR SHIFT
RAIL
REVERSE
SHIFT
FORK J8921-1075
Fig. 41 Shift Rail Identification

3-4
SHIFT RAIL
Fig. 42 Removing Shift Rail C-Rings

(3) Remove shift fork set screws (Fig. 43).
SHIFT FORK
SET SCREWS
J8921-1072
i
Fig. 43 Removing Shift Fork Set Screws

(4) Remove 3-4 shift rail from shift fork and inter
mediate plate (Fig. 44).
(5) Remove 3-4 shift rail interlock plug from inter
mediate plate with magnet (Fig. 45). FORK J8921-1076
(6) Remove 1-2 shift rail from shift fork and inter
Fig. 46 Removing 1-2 Shift Rail
mediate plate (Fig. 46).
(7) Remove 1-2 shift rail interlock pin from shift (9) Lift reverse shift fork upward and remove fifth
rail (Fig. 47). gear shift rail lock ball (Fig. 49).
(10) Remove 3-4 shift fork (Fig. 50).
21-46 I X 15 MANUAL TRANSMISSION
1-2 SHIFT
Fig. 47 Removing 1-2 Shift Rail Interlock Pin
Fig. 50 Shift Fork Removal
Fig. 48 Removing 1-2 Shift Rail Interlock Plug

(11) Remove 1-2 shift fork (Fig. 50).
Fig. 49 Removing Fifth Gear Shift Rail Lock Ball C-RING
(12) Remove reverse shift rail C-ring with two

equal length and size screwdrivers (Fig. 51).
J8921-1081
(13) Remove reverse shift rail and fork (Fig. 52).
Fig. 51 Removing Reverse Shift Rail C-Ring
J (14) Remove interlock pin from reverse shift rail
(Fig. 53).
(15) Position shift rails, shift forks, lock balls, in
terlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying com
ponents during inspection and assembly.
Fig. 52 Removing Reverse Shift Rail And Fork
Fig. 54 Removing Bearing Snap Rings
Fig. 53 Removing Reverse Shift Rail Interlock Pin

OUTPUT SHAFT AND CLUSTER GEAR
REMOVAL
(1) Remove output shaft rear bearing snap ring
(Fig. 54).
(2) Remove cluster gear rear bearing snap ring Fig. 55 Unseating Output Shaft Rear Bearing
(Fig. 54).
(3) Tap end of output shaft with mallet to unseat
and start rear bearing out of intermediate plate (Fig.
55).
(4) Remove output shaft by rocking it lightly until
rear bearing comes out of intermediate plate (Fig.
56).
(8) Remove output shaft pilot bearing from input
J8921-1089
Fig. 56 Input/Output Shaft Assembly Removal
(5) Remove cluster gear by pulling it straight out Fig. 59 input Shaft Removal
of rear bearing (Fig. 57). shaft (Fig. 60).
(6) Remove cluster gear rear bearing from inter (9) Remove synchro ring from input shaft (Fig. 61).
mediate plate (Fig. 58). (10) Remove bearing snap ring and press bearing
off input shaft (Fig. 61).
Fig. 57 Cluster Gear Removal
Fig. 60 Removing input Shaft Pilot Bearing
SYNCHRO
BEARING RING
Fig. 58 Removing Cluster Gear Rear Bearing

Fig. 61 input Shaft Components
(7) Remove input shaft from output shaft (Fig. 59).
THRUST REVERSE 3-4 • First gear clearance should be 0.10 - 0.40 mm

WASHER GEAR
SECOND
SYNCHRO (0.003 - 0.0197 in).
FIRST AND H U B SLEEVE
GEAR GEAR • Second—third gear clearance should be 0.10 - 0.30
AND
HUB i mm (0.003 - 0.0118 in.).
(2) If first gear thrust clearance is incorrect, re
place gear and thrust washer. I f second or third
gear clearance i s incorrect, either gear and
bearing, or output shaft flange is worn. Refer to
output shaft inspection i n Cleaning and Inspec
tion section.
(3) Press fifth gear and rear bearing off rear of
output shaft.
(4) Remove thrust washer, pin, and first gear and
bearing (Fig. 62).
(5) Remove first/reverse hub snap ring (Fig. 63).
(6) Remove synchro ring.
OUTPUT (7) Press reverse gear and first/reverse hub off
SHAFT
1ST 2ND FLANGE
shaft as assembly.
CLEARANCE CLEARANCE (8) Remove remaining synchro ring and second
J8921-1092 gear and bearing (Fig. 63).
(9) Remove snap ring at front of output shaft (Fig.
Fig. 62 Checking Output Shaft Gear Thrust 63).
Clearance (10) Press 3-4 hub and sleeve off output shaft as
OUTPUT SHAFT DISASSEMBLY assembly (Fig. 63).
(1) Measure thrust clearance of output shaft first, (11) Remove synchro ring.
second and third gears with feeler gauge (Fig. 62). (12) Remove third gear and needle bearing (Fig.
63).
BEARING RING J8921-1093
Fig. 63 Output Shaft And Gears

TRANSMISSION CLEANING AND INSPECTION

Clean the transmission components in solvent. Dry
the cases, gears, shift mechanism and shafts with
compressed air. Dry the bearings with clean, dry
shop towels only. Never use compressed air on
the bearings. This could damage the bearing
rollers.
Replace components that are obviously worn,
cracked, chipped or damaged in any way.
Inspect the transmission case. Replace the case if
cracked or porous or if any of the bearing and gear
bores are damaged.
Output Shaft Inspection

Measure thickness of the output shaft flange with
a micrometer (Fig. 64). Minimum allowable flange
thickness is 4.70 mm (0.185 in).
If shaft flange thickness is OK but previously
measured second/third gear thrust clearance
was incorrect (Fig. 62), replace the necessary
gear and needle bearing as an assembly.
Check diameter of the first, second and third gear
bearing surfaces of the output shaft (Fig. 64). Mini
mum allowable diameters are:
• 38.86 mm (1.529 in.) for first gear surface
• 46.86 mm (1.844 in.) for second gear surface
• 37.86 mm (1.490 in.) for third gear surface
Check output shaft runout with V-blocks and a dial
indicator (Fig. 64). Maximum allowable runout is
0.06 mm (0.0024 in.).
Replace the output shaft if any surface measured
fails to meet stated tolerance.
Cluster Gear Inspection

Inspect the cluster gear teeth. Replace the gear if
any teeth are worn or damaged or if the bearing sur
faces are damaged. Fig. 64 Checking Output Shaft Tolerances
Check diameter of the cluster gear journal with a
micrometer (Fig. 65). Minimum allowable diameter
is 27.860 mm (1.096 in.).
Check condition of the cluster gear front bearing.
Replace the bearing if worn, noisy, or damaged.
GEAR AND SYNCHRO INSPECTION

Install the synchro rings on their respective gears.
Rotate each ring on the gear and note synchro ac
tion. Replace any synchro ring that exhibits a lack of
braking action or binds on the gear. Also replace any Fig. 65 Checking Cluster Gear Journal Diameter
ring that is worn or has chipped or broken teeth. Maximum allowable clearance is 0.16 mm (0.0063
Measure end clearance between the synchro ring in.). If any gear exhibits excessive clearance, replace
and the gear with a feeler gauge (Fig. 66). Clearance the gear and needle bearing.
should be 0.06 mm - 1.6 mm (0.024 - 0.063 in.). Check clearance between the shift forks and syn
Install the needle bearings in the first, second and chro sleeves with a feeler gauge (Fig. 68). Clearance
third gears. Then install the gears on the output should not exceed 1.0 mm (0.039 in.). Replace the
shaft and check shaft-to-gear clearance with a dial synchro sleeve (and matching hub) if clearance ex
indicator (Fig. 67). ceeds the stated limit.
SHIFT
FORK
FEELER
GAUGE
SYNCHRONIZER
RING
J8921-48
J8921-49
Fig. 66 Checking Synchro Ring End Clearance
Fig. 68 Checking Shift Fork-To-Sleeve Clearance
CHECK REVERSE
BUSHING IDLER
FOR W E A R GEAR
OR DAMAGE
OUTPUT
SHAFT
J8921-1096
GEAR
BEING
Fig. 69 Reverse Idler Gear Bushing
CHECKED
thread inserts if necessary. However, do not attempt
to repair if the cracks are evident around any
J8921-47 threaded hole.
Inspect the reverse pin in the adapter/extension
Fig. 67 Checking Gear-To-Shaft Clearance housing. Replace the pin if worn or damaged. Refer
Check condition of the reverse idler gear bushing to the replacement procedure in the Transmission
(Fig. 69). Replace the gear if the bushing is damaged Assembly section.
or worn.
T R A N S M I S S I O N A S S E M B L Y AND A D J U S T M E N T
Gear Case, Housing And Intermediate Plate Lubricate the transmission components with Mopar
Clean the case, housing and plate with solvent and 75W-90 gear lubricant during assembly. Use petro
dry with compressed air. Replace any component that leum jelly to lubricate seal lips and/or hold parts in
is cracked, warped or damaged in any way. place during installation.
Inspect the threads in the case, housing and plate.
Minor thread damage can be repaired with steel
21-52 AX 15 MANUAL TRANSMISSION
FRONT REARING, SEAL AND PIN (3) Install new oil seals in front bearing retainer
J
INSTALLATION and adapter housing (Fig. 72). Installation depth for
(1) Press front bearing on input shaft. Then secure bearing retainer seal is 10.5 - 11.5 mm (0.414 - 0,453
bearing with thickest snap ring that will fit in shaft in.).
groove (Fig. 70).
SELECT-FIT
SNAP RING
FRONT
BEARING
RETAINER
I.D. SNAP RING MM (IN.)

MARK THICKNESS
A 2.10-2.15 (0.0827 - 0.0846)
B 2.15-2.20 (0.0846 - 0.0866)
C 2.20 - 2.25 (0.0866 - 0.0886)
D 2.25 - 2.30 (0.0886 - 0.0906)
E 2.30-2.35 (0.0906 - 0.0925)
F 2.35 - 2.40 (0.0925 - 0.0945)
G 2.40 - 2.45 (0.0945 - 0.0965)
J8921-1097
Fig. 70 Selecting Input Shaft Front Bearing Snap SEAL

Ring INSTALLER
J8921-52
(2) Press front bearing on cluster gear. Then se
cure bearing with thickest snap ring that will fit in
Fig. 72 Oil Seal Installation
ring groove on gear (Fig. 71).
(4) Install reverse shaft and shaft retaining pin in
CLUSTER adapter housing. Then install access hole plug with
GEAR
torx bit (Fig. 73).
REVERSE
SHAFT
RETAINING
PIN
I.D. SNAP RING

MM (IN.)
MARK THICKNESS
A 2.00 - 2.05 (0.0787 - 0.0807) ACCESS
B 2.05-2.10 (0.0007 - 0.0827) PLUG
C 2.10-2.15 (0.0827 - 0.0846)
D 2.15-2.20 (0.0846 - 0.0866)
E 2.20 - 2.25 (0.0866 - 0.0886)
J8921-1098
Fig. 71 Selecting Cluster Gear Front Bearing Snap
Ring J8921-53
Fig. 73 Installing Reverse Shaft Pin

J(5) Lubricate reverse shaft and gear components
with Mopar 75W-90 gear lubricant.
OUTPUT SHAFT ASSEMBLY

(1) Lubricate output shaft journals, gears and nee
dle bearings with Mopar 75W-90 gear lubricant.
(2) Install third gear and needle bearing on shaft
(Fig. 63)
(3) Install synchro ring on third gear (Fig. 63).
(4) Assemble 1-2 and 3-4 synchro hubs and sleeves
(Fig.74).
(5) Install inserts and springs in synchro sleeves.
Position open ends of springs 180° apart as shown
I.D. S N A P RING
(Fig. 75). M M (IN.)
MARK THICKNESS
A 1.80 - 1 . 8 5 (0.0709 - 0.0728)
B 1 . 8 5 - 1.90 (0.0728 - 0.0748)
C 1 . 9 0 - 1.95 (0.0748 - 0.0768)
D 1.95-2.00 (0.0768 - 0.0787)
E 2.00 - 2.05 (0.0787 - 0.0807)
F 2.05-2.10 (0.0807 - 0.0827)
G 2.10-2.15 (0.0827 - 0.0846)
J8921-1101
Fig. 76 Installing 3-4 Synchro Hub Snap Ring

FEELER THIRD
GAUGE GEAR
J8921-1099
Fig. 74 Synchro Sieeve And Hub Identification

SYNCHRO INSTALL INSERT
Fig. 77 Checking Third Gear Clearance

(10) Install second gear and needle bearing on
shaft (Fig. 78).
(11) Install synchro ring on second gear (Fig. 78).
(12) Assemble first/reverse hub, insert springs, in
serts, reverse gear and 1-2 sleeve (Fig. 78). Be sure
Fig. 75 Insert Spring Position spring ends are 180° apart. Note that splines in
(6) Install 3-4 synchro hub and sleeve on output hub bore are chamfered on one side. Install hub
shaft. Press hub onto shaft if necessary. so chamfered side faces front of output shaft.
(7) Install 3-4 synchro hub snap ring (Fig. 76). Use (13) Press assembled hub and sleeve on output
thickest snap ring that will fit in shaft groove. shaft.
(8) Verify third gear thrust clearance with feeler (14) Install selective snap ring (Fig. 78). Use thick
gauge (Fig. 56). Clearance should be 0.10 - 0.25 mm est snap ring that will fit in output shaft groove.
(0.004 - 0.010 in.). (15) Install synchro ring on first gear (Fig. 79).
(9) Lubricate remaining output shaft gears and (16) Install first gear spacer on shaft and against
bearings with gear lubricant. selective fit snap ring (Fig. 79).
21 - 54 AX 15 MANUAL TRANSMISSION
SECOND REVERSE GEAR

GEAR AND 1-2 SLEEVE
TAP
SNAP
RING
INTO
PLACE
I.D. SNAP RING

AAM (IN.)
MARK THICKNESS
I.D. S N A P RING
B 2.35 - 2.40 (0.0925 - 0.0945) MARK THICKNESS
AAM (IN.)
C 2.40 - 2.45 (0.0945 - 0.0965)
A 2.75 - 2.80 (0.1083-0.1102)
D 2.45 - 2.50 (0.0965 - 0.0984)
B 2.80 - 2.85 (0.1002-0.1122)
E 2.50 - 2.55 (0.0984 - 0.1004)
C 2.85 - 2.90 (0.1122 - 0.1142)
F 2.55 - 2.60 (0.1004 - 0.1024)
D 2.90 - 2.95 (0.1142-0.1161)
G 2.60 - 2.65 (0.1024-0.1043)
E 2.95 - 3.00 (0.1161 - 0 . 1 1 8 1 )
J8921-1102
F 3.00 - 3.05 (0.1181 - 0 . 1 2 0 1 )
G 3.05-3.10 (0.1201 - 0 . 1 2 2 0 )
Fig. 78 Second Gear And Synchro Assembly H 3.10-3.15 (0.1220 - 0.1240)
J 3.15-3.20 (0.1240-0.1260)
(17) Install first gear and needle bearing (Fig. 79) K 3.20 - 3.25 (0.1260-0.1280)
on output shaft. L 3.25 - 3.30 (0.1280-0.1299)
(18) Install locating pin and thrust washer on M 3.30 - 3.35 (0.1299 - 0.1319)
shaft (Fig. 79). J8921-1104
SYNCHRO SPACER PIN BEARING FIFTH Fig. 80 Selecting Fifth Gear Snap Ring
RING GEAR
leum jelly and install bearing in shaft (Fig. 60).
(23) Install input shaft on output shaft (Fig. 59).
Be sure output shaft hub is fully seated in pilot bear
ing.
OUTPUT SHAFT AND CLUSTER GEAR

INSTALLATION
(1) Mount intermediate plate in vise (Fig. 24).
(2) Lubricate cluster gear journal and rear bearing
with petroleum jelly or gear lubricant.
(3) Install cluster gear rear bearing in intermedi
ate plate (Fig. 81). Be sure snap ring groove in bear
FIRST NEEDLE THRUST ing is rearward as shown.
GEAR BEARING WASHER J8921-1103
(4) Start cluster gear into bearing (Fig. 57). Then
hold bearing and push gear into place. Use plastic or
Fig. 79 First And Fifth Gear Components
rawhide mallet to seat bearing if necessary.
(19) Press rear bearing on shaft. Position bearing (5) Start output shaft rear bearing in intermediate
snap ring groove so it is closest to end of output plate. Push shaft rearward and tap intermediate
shaft. plate with mallet to seat bearing.
(20) Check first and second gear thrust clearance
with feeler gauge (Fig. 62).
• First gear clearance should be 0.10 - 0.40 mm
(0.003 - 0.0197 in.)
• Second gear clearance should be 0.10 - 0.30 mm
(0.003 - 0.0118 in.)
(21) Press fifth gear onto output shaft. Then install
select fit snap ring (Fig. 80). Use thickest snap ring
that will fit in shaft groove.
(22) Lubricate input shaft pilot bearing with petro-
J AX 1 5 MANUAL TRANSMISSION 21 - 55
Fig. 81 Installing Cluster Gear Rear Bearing Fig. 83 installing Reverse Idler Gear And Shaft
Fig. 82 Installing Rear Bearing Snap Rings

(7) Install reverse idler gear and shaft (Fig. 83).
(8) Position rear bearing retainer over output shaft
and rear bearing. Be sure bearing retainer tab is
engaged in reverse idler shaft notch (Fig. 84).
(9) Install and tighten rear bearing retainer bolts
to 18 N*m (13 ft-lbs).
Fig. 85 Shift Rail Ball-Plug-Pin Position

SHIFT RAIL AND FORK INSTALLATION
The shift rail interlock pins, balls and plugs must
be installed in the correct sequence for proper shift
ing. Refer to the installation diagram (Fig. 85) dur
ing assembly.
Coat the intermediate plate shift rail bores and
the interlock balls, pins and plugs with a heavy
coating of petroleum jelly before assembly. The
jelly will hold the interlock components in place
making installation easier. Use a pencil magnet
to hold and insert the interlocks. Then use a
small screwdriver to push the interlock compo
nents into place.
(1) Coat reverse rail interlock pin with petroleum
jelly and install pin in rail (Fig. 86).
(2) Install reverse shift rail in intermediate plate
(Fig. 87).
(3) Install reverse shift rail C-ring (Fig. 51).
J
Fig. 87 Installing Reverse Shift Rail And Fork Fig. 89 Installing Reverse Shift Rail Lock Rail
(4) Position 1-2 and 3-4 shift forks in synchro (8) Install 1-2 shift rail in intermediate plate and
sleeves (Fig. 88). 1-2 fork (Fig. 92).
(5) Coat reverse rail lock ball with petroleum jelly.
Then tilt reverse shift fork upward and insert ball in
intermediate plate (Fig. 89).
Fig. 90 Installing 1-2 Shift Rail Interlock Plug

1-2 S H I F T
Fig. 88 Shift Fork Installation

(6) Coat 1-2 shift rail interlock plug with petro
leum jelly and install it in intermediate plate bore Fig. 91 Installing 1-2 Shift Rail Interlock Pin
(Fig. 90).
(7) Coat 1-2 shift rail interlock pin with petroleum (9) Coat 3-4 shift rail interlock plug with petro
jelly and insert it in shift rail (Fig. 91). leum jelly and install plug in intermediate plate
(Fig. 93).
INTERMEDIATE (12) Install and tighten shift fork setscrews to 20

N«m (14 ft. lbs.) torque (Fig. 95).
(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96).
(14) Insert fifth gear shift rail through reverse
shift fork. Then slide rail into intermediate plate
just far enough to secure interlock ball. Do not
fully install shift rail at this time.
S H I F T FORK
SET SCREWS
tVKK J8921-1076
Fig. 92 Installing 1-2 Shift Rail

(10) Install 3-4 shift rail in intermediate plate and
in both shift forks (Fig. 94).
(11) Verify that none of interlock balls, plugs, or
pins were displaced during shift rail installation.
J8921-1072
Fig. 95 Installing Shift Fork Set Screws
Fig. 93 Installing 3-4 Shift Rail Interlock Plug

3-4
S H I F T RAIL
Fig. 96 Installing Shift Rail C-Rings

FIFTH-REVERSE GEAR AND SHIFT
COMPONENT INSTALLATION
(1) Install thrust ring lock ball in cluster gear
journal (Fig. 97). Use petroleum jelly to hold ball in
place.
(2) Install fifth gear thrust ring (Fig. 98). Be sure
thrust ring notch fits over lock ball.
(3) Assemble counter fifth gear, synchro sleeve, in
serts and insert springs (Fig. 99).
(4) Lubricate two-piece bearing with petroleum
jelly and install it in counter fifth gear (Fig. 100).
(5) Install counter fifth gear and synchro assembly
Fig. 94 Installing 3-4 Shift Rail on cluster gear journal (Fig. 101).
(6) Install synchro ring in synchro sleeve (Fig.
102).
Fig. 100 Installing Counter Fifth Gear Bearing

Fig. 97 Installing Thrust Ring Lock Ball
(8) Install fifth gear selective snap ring (Fig. 104).
Use thickest snap ring that will fit in shaft groove.
Fig. 101 Installing Counter Fifth Gear And Sleeve
J8921-1112
Fig. 99 Assembling Fifth Gear And Synchro

Assembly
(7) Install fifth spline gear on cluster journal (Fig. Fig. 102 Installing Fifth Gear Synchro Ring
103). Tap spline gear into place with plastic mallet if (9) Install reverse shift head and rail (Fig. 105).
necessary. Then install lock ball in shift head.
21-60 AX 1 5 MANUAL TRANSMISSION
FIFTH SPLINE GEAR
REVERSE
SHIFT
HEAD
AND
SHIFT
RAIL
Fig. 103 installing Fifth Spline Gear Fig. 105 Installing Reverse Shift Head And Rail
FIFTH GEAR
S H I F T FORK
FIFTH GEAR
SYNCHRO SLEEVE
J892M060
Fig. 106 Installing Fifth Gear Shift Fork

FIFTH GEAR
I.D. S N A P RING
AAM (IN.) S H I F T RAIL
MARK THICKNESS
A 2.85 - 2.90 (0.1122 - 0.1142)
B 2.90 - 2.95 (0.1142-0.1161)
C 2.95 - 3.00 (0.1161 - 0 . 1 1 8 1 )
D 3.00 - 3.05 (0.1181 - 0 . 1 2 0 1 )
E 3.05-3.10 (0.1201 - 0 . 1 2 2 0 )
F 3.10-3.15 (0.1220-0.1240)
G 3.15-3.20 (0.1240 - 0.1260)
H 3.20 - 3.25 (0.1260 - 0.1280)
J8921-1114
Fig. 104 Installing Fifth Gear Snap Ring

(10) Position fifth gear shift fork in synchro sleeve
(Fig. 106).
(11) Install fifth gear shift rail (Fig. 107). Slide
rail through fork, shift head, intermediate plate and
reverse shift fork. Be sure interlock ball is not dis Fig. 107 Installing Fifth Gear Sft/ft Rail
placed during installation.
(12) Align screw holes in shift fork and rail and in
stall set screw (Fig. 108). Tighten screw to 20 N»m
(16) Verify that shift arm shoe is engaged in re

verse idler gear. Then secure shift arm to pin on re
verse fork with new E-clip.
Fig. 108 Shift Fork Set Screw Installation

(13) Install lock balls and springs in intermediate
plate (Fig. 109). Then install and tighten lock ball
plugs to 19 N»m (14 ft. lbs.) torque. Fig. 110 Reverse Shift Arm And Bracket Installation
GEAR CASE AND ADAPTER INSTALLATION
(1) Dismount intermediate and gear assemblies
from vise.
(2) Clean mating surfaces of intermediate plate
and transmission gear case with wax and grease re
mover. Then wipe dry with a clean cloth.
(3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas
ket Maker to mating surface of gear case. Keep
sealer bead inside bolt holes as shown (Fig. 111).
(4) Install gear case (Fig. 112). Align shift rails
and bearings in case and tap case into position.
(5) Verify that gear case is seated on intermediate
plate dowel pins.
(6) Install front bearing snap rings (Fig. 113).
SEALER BEAD
Fig. 109 Detent Ball And Spring Installation J8921-1118
(14) Install reverse shift arm bracket (Fig. 110). Fig. 111 Applying Sealer To Gear Case
Tighten bracket bolts to 18 N*m (13 ft. lbs.) torque.
(15) Install reverse shift arm (Fig. 110). Position
arm on reverse fork pin and engage it with pin on
shift arm bracket.
21-12 AX 15 MANUAL TRANSMISSION
GEAR INTERMEDIATE (7) Clean gear case and front bearing retainer
PLATE sealing surfaces with wax and grease remover. Then
wipe dry with a clean cloth.
(8) Install new seal in front bearing retainer. Then
lubricate seal lip with petroleum jelly. Installation
depth for seal is 10.5 - 11.5 mm (0.413 - 0.453 in.).
(9) Apply a 3 mm (1/8 in.) wide bead of Mopar
Gasket Maker to front bearing retainer sealing sur
face.
(10) Align and install front bearing retainer (Fig.
114). Be sure retainer is properly seated on case and
bearings.
(11) Install and tighten front bearing retainer
J8921-1051 (12) On 2-wheel drive models, install speedometer
gear, lock ball and retaining rings (Fig. 115). Be sure
Fig. 112 Installing Gear Case lock ball is engaged in gear.
SNAP SNAP
RING RING
OUTPUT
SHAFT SPEEDOMETER
GROOVES GEAR
J8921-1119
Fig. 115 Speedometer Gear Installation (2WD

Models)
FRONT
BEARING
(13) Inspect condition o reverse pin in adapter/ex
SNAP tension housing (Fig. 116). If pin is worn or dam
RINGS aged, replace it as follows:
(a) Remove roll pin access plug (Fig. 117).
Fig. 113 Installing Front Bearing Snap Rings (b) Tap roll pin out of housing with pin punch
(Fig. 118). Then remove old reverse pin.
(c) Install new reverse pin and secure it with roll
#
FRONT
pin. Then install and tighten access plug to 19 N m
BEARING (14 ft. lbs.) torque.
RETAINER (14) Clean sealing surfaces of adapter or extension
housing and intermediate plate with wax and grease
remover. Then wipe dry with a clean cloth.
(15) Apply 3 mm (1/8 in.) wide bead of Mopar Gas
ket Maker to sealing surface of adapter or extension
housing. Keep sealer bead inside bolt holes as shown
in Figure 111.
(16) Align and install adapter or extension housing
on intermediate plate (Fig. 119). Be sure housing is
seated on intermediate plate dowel pins.
J892MQ46
Fig. 114 Installing Front Bearing Retainer

J AX 15 MANUAL TRANSMISSION 21 - 5 3
REVERSE ADAPTER
PIN HOUSING ,
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ J892J-1120 INTERMEDIATE PLATE J8921-1G44
Fig. 116 Reverse Pin Position Fig. 119 Adapter/Extension Housing Installation
REVERSE (18) Install detent ball (Fig. 120).
PIN (19) Install detent spring (Fig. 121).
ACCESS
PLUG
(20) Install detent access plug (Fig. 122). Tighten
plug to 19 N»m (14 ft. lbs.) torque.
DETENT z^^^^^^mK. "VV V
BALL " imm^^mmmm^
Fig. 117 Access Plug Removal/Installation
1123
Fig. 120 Installing Detent Ball
J8921-1122
Fig. 118 Roll Pin Removal/Installation

(17) Coat threads of housing attaching bolts with
silicone sealer. Then install and tighten bolts to 37
N*m (27 ft. lbs.) torque.
Fig. 121 Installing Detent Spring
(23) Align shift arm with shaft and push shaft into
arm.
(24) Rotate shift arm shaft until set screw holes in
shaft and arm are aligned.
(25) Install and tighten shift arm set screw to 38
N-m (28 ft. lbs.) torque (Fig. 125).
(26) Install and tighten restrictor pins to 19 N*m
(14 ft. lbs.) torque (Pig. 125).
(27) Install and tighten shift arm shaft access plug
to 19 N*m (14 ft. lbs.) torque (Fig. 126).
Fig. 122 Installing Detent Access Plug

(21) Lubricate shift arm shaft and install it in
adapter housing (Fig. 123).
(22) Position shift arm in adapter housing (Fig.
124). Be sure arm is engaged in shift rails.
Fig. 125 Set Screw And Restrictor Pin Installation
Fig. 126 Access Plug Installation

(28) Position new shift tower gasket on adapter
housing (Fig 127).
(29) Install shift tower (Fig. 128). Tighten tower
attaching bolts to 18 N«m (13 ft. lbs.) torque.
(30) Install new gasket on backup light switch and
install switch. Tighten switch to 37 N-m (27 ft. lbs.)
torque.
(31) Install new washer on drain plug. Then install
and tighten plug to 37 N*m (27 ft. lbs.) torque.
Fig. 124 Shift Arm Installation (32) If transmission will be filled with gear lubri
cant before installation, place transmission in a level
J
position. Then fill with Mopar 75W-90, grade GL-5
gear lubricant. Correct fill level is to bottom edge of
fill plug hole.
(33) Install new washer on fill plug. Then install
and tighten plug to 37 N»m (27 ft. lbs.) torque.
(34) Install clutch housing and hydraulic concen
tric bearing.
(35) On 2-wheel drive models, install new seal in
extension housing with suitable size installer tool
(Fig. 129). Lubricate seal lips with petroleum jelly
before installation.
(36) On 2-wheel drive models, install speedometer
driven gear, speedometer adapter and vehicle speed
sensor.
Fig. 128 Shift Tower Installation

.SHIFT
TOWER EXTENSION HOUSING SEAL
-1033
Fig. 127 Shift Tower Gasket Installation
Fig. 129 Installing Extension Housing Seal—2WD

Models
21 - i i 32RH AUTOMATIC TRANSMISSION J
32RH AUTOMATIC TRANSMISSION
INDEX
page page
32RH In-Vehicle Service 95 32RH Transmission Overhaul 107
3 2 R H Transmission Diagnosis 69 3 2 R H Transmission Removal and Installation . . . 103
GENERAL INFORMATION
TRANSMISSION APPLICATION TRANSMISSION CONTROLS AND COMPONENTS
YJ models are equipped with the Chrysler 32RH The transmission hydraulic control system provides
automatic transmission. The 32RH is a 3-speed, fully automatic operation. The system performs five basic
automatic transmission with a gear type oil pump, functions, which are:
two clutches and bands and a planetary gear system • pressure supply
(Fig. 1). • pressure regulation
• flow control
TORQUE CONVERTER • clutch/band apply and release
A three element, torque converter is used for all • lubrication
applications. The converter consists of the front
Pressure Regulation
cover, impeller, stator, turbine, hub and overrunning
clutch. The oil pump generates the fluid working pressure
The impeller is connected to the engine crankshaft needed for operation and lubrication. The pump is
driven by the torque converter. The converter is con
through the front cover which is welded to the impel
nected to the engine crankshaft through the drive-
ler. The turbine is splined to the transmission input
plate.
shaft and the stator is splined to the transmission re The pressure regulator valve maintains operating
action shaft. (line) pressure. The regulator valve is located in the
The torque converter is a welded assembly and is valve body. The amount of line pressure developed is
not a repairable component. The converter is serviced controlled by throttle pressure, which is dependent
as an assembly. on the degree of throttle opening.
The governor valve is operated by the transmission
RECOMMENDED FLUID output shaft. Governor pressure increases in propor
The preferred fluid for 32RH transmissions is Mo tion to vehicle speed.
par ATF Plus, Type 7176. Mopar Dexron II is also The throttle valve determines line pressure and
acceptable and can used when ATF Plus is not shift speed. The throttle valve also controls upshift
readily available. and downshift speeds by regulating pressure in con
Transmission fluid capacity is approximately 17 junction with throttle position.
pints (7.9 liters). This is the approximate amount of
fluid required to fill the transmission and torque con Shift Walwes
verter after overhaul. The manual valve is operated by the gearshift link
age and provides the operating range selected by the
TRANSMISSION IDENTIFICATION driver.
The transmission identification numbers are The 1-2 shift valve provides automatic 1-2 or 2-1
stamped on the left side of the case just above the oil shifts and the 2-3 shift valve provides automatic 2-3
pan gasket surface (Fig. 2). The first set of numbers or 3-2 shifts. The kickdown valve provides forced 3-2
is the transmission part number. The next set of code or 3-1 downshifts depending on vehicle speed. Down
numbers set is the date of build. The final set of code shifts occur when the throttle is opened beyond
numbers represents the transmission serial number. downshift detent position which is just before wide
open throttle.
SPECIFICATIONS The 2-3 valve throttle pressure plug provides 3-2
Service specifications and torque values are located downshifts with varying throttle openings and de
at the end of this group. Refer to the specifications pending on vehicle speed. The 1-2 shift control valve
during service operations. transmits 1-2 shift pressure to the accumulator pis
ton to control kickdown band capacity on 1-2 upshifts
32RH AUTOMATIC TRANSMISSION 21 - 67
(7) CONVERTER ( n ) O U T P U T SHAFT
( ? ) OIL PUMP (12) S E A L
( ? ) F R O N T CLUTCH (13) A D A P T E R H O U S I N G
(7) REAR CLUTCH (u) PARK LOCK R O D
( ? ) F R O N T P L A N E T A R Y GEAR S E T @ VALVE BODY
( £ ) REAR P L A N E T A R Y GEAR S E T (?6) S U N GEAR DRIVING S H E L L
( ? ) L O W A N D REVERSE (REAR) BAND @ OIL FILTER
( ? ) O V E R R U N N I N G CLUTCH (ji) KICK D O W N (FRONT) B A N D
(?) GOVERNOR (19) I N P U T S H A F T
(jo) BEARING (20) PARK GEAR
J9021-30
F/g. T 32f?H Automatic Transmission

21 - 68 32RH AUTOMATIC TRANSMISSION J
Clutches-Bands-Servos-Accumulator
Thefront/rearclutch pistons and servo pistons are
actuated by line pressure. When line pressure is re-
mqved, the pistons are released by spring tension.
On 2-3 upshifts, the front servo piston is released
by spring tension and hydraulic pressure. The accu
mulator controls hydraulic pressure on the apply side
of the front servo during 1-2 upshifts and at all
throttle openings.
Gearshift And Parking Lock Controls

The gearshift lever provides six operating posi
tions: Park (P), Reverse (R), Neutral (N), and the D,
2 and 1 forward drive ranges.
1 position provides overrun braking when the
throttle is released. However, upshifts are not pro
Fig. 2 Transmission Identification vided in 1 position. 1-2 up shifts will occur in 2 posi
The shuttle valve has two functions. First is fast tion but no 2-3 upshift will take place. D position
front band release and smooth engagement during provides 1-2, 2-3 upshifts and 3-2 and 3-1 downshifts.
A park/neutral position switch controls engine
lift-foot 2-3 upshifts. The second is to regulate front
starting. The switch is designed to allow engine
clutch and band application during 3-2 downshifts.
starts only in park or neutral positions.
The transmission parking lock mechanism is en
gaged when the shift lever is moved into the Park
detent. The mechanism consists of a pawl that en
gages a gear on the output shaft.
J 32RH TRANSMISSION DIAGNOSIS 21 - 69
3 2 R H T R A N S M I S S I O N DIAGNOSIS
INDEX
page page
Air Pressure Test 73 Gearshift Linkage 70
Analyzing the Road Test . . . . . . . . . . . . . . . . . . . 70 General Information 69
Converter Housing Leak Diagnosis 73 Hydraulic Pressure Test 71
Converter Stall Test 72 Preliminary Diagnosis 69
Diagnosis Guides and Charts 76 Road Test 70
Fluid Level and Condition 69 Transmission Throttle Cable Adjustment 70
GENERAL INFORMATION (6) Perform air pressure test to check clutch-band

Automatic transmission problems are generally the operation.
result of:
• poor engine performance Vehicle Is Disabled
• incorrect fluid level (1) Check fluid level and condition.
• incorrect linkage adjustment (2) Check for broken, disconnected throttle link
• incorrect band adjustment age.
• incorrect hydraulic control pressure adjustments (3) Check for cracked, leaking cooler lines, or
• hydraulic component malfunctions loose, missing pressure port plugs.
• mechanical component malfunctions. (4) Raise vehicle, start engine, shift transmission
Begin diagnosis by checking the easily accessible into gear and note following:
items such as fluid level, fluid condition and control (a) If propeller shafts turn but wheels do not,
linkage adjustment. A road test will determine if fur problem is with differential or axle shafts.
ther diagnosis is necessary. (b) If propeller shafts do not turn and transmis
Procedures outlined in this section should be per sion is
formed in the following sequence to realize the most noisy, stop engine. Remove oil pan, and check for
accurate results: debris. If pan is clear, remove transmission and
• Preliminary diagnosis check for damaged drive plate, converter, oil pump
• Check fluid Level and condition
or input shaft.
• Check control linkage Adjustment
(c) If propeller shafts do not turn and transmis
• Road test
• Stall test sion is not noisy, perform hydraulic pressure test to
• Hydraulic pressure test determine if problem is a hydraulic or mechanical.
• Air pressure tests
• Leak Tests FLUID LEVEL AND CONDITION
• Analyze test results and consult diagnosis charts (1) To avoid false readings, which could produce
under or over fill condition, do not check level until
PRELIMINARY DIAGNOSIS fluid is at normal operating temperature.
Two basic procedures are required. One procedure (2) Shift transmission into Neutral.
for vehicles that are driveable and an alternate pro (3) Apply parking brakes.
cedure for disabled vehicles (will not back up or (4) Operate engine at curb idle speed.
move forward).
WARNING: W H E N P E R F O R M I N G U N D E R H O O D
Vehicle Is Driveable O P E R A T I O N S W I T H T H E ENGINE RUNNING, K E E P
(1) Check fluid level and condition. Y O U R H A N D S W E L L A W A Y FROM H O T OR R O T A T
(2) Adjust throttle cable and gearshift linkage if ING ENGINE C O M P O N E N T S . DO N O T W E A R
complaint was based on delayed, erratic, or harsh L O O S E A R T I C L E S O F CLOTHING WHICH C O U L D
shifts. B E C O M E E N T A N G L E D IN ENGINE C O M P O N E N T S
(3) Road test vehicle and note transmission operat OR A C C E S S O R I E S .
ing characteristics.
(4) Perform stall test if complaint is based on slug (5) Clean dipstick filler cap and tube before remov
gish, low speed acceleration or abnormal throttle ing dipstick.
opening needed to maintain normal speeds with (6) Remove dipstick and inspect fluid level. Correct
properly tuned engine. level is to FILL mark. Acceptable level is between
(5) Perform hydraulic pressure tests. ADD and FULL marks.
21 - 7 0 32RH TRANSMISSION DIAGNOSIS J
(7) Check fluid condition. Fluid should be dark to Operate the transmission in all gear ranges. Check
light red in color and free of dirt or debris. for slippage and shift variations. Note whether the
(8) If fluid is discolored or smells burned but trans shifts are harsh, spongy,
mission operation was OK, check cooler flow, flush delayed, early, or if part throttle downshifts are
cooler and lines and change fluid and filter. Then sensitive.
road test again to confirm proper operation. Watch closely for slippage or engine flare which
(9) If fluid is black or dark brown, burned/turned usually indicates clutch, band or overrunning clutch
to sludge, contains large quantities of metal or fric problems. If the condition is advanced, an overhaul
tion material particles, transmission will need over may be necessary to restore normal operation.
haul. Especially if problems were evident during A slipping clutch or band can often be determined
road test and preliminary diagnosis. Fluid cooler by comparing which internal units are applied in the
should also be flow tested and flushed if necessary. various gear ranges. The Clutch and Band Applica
tion chart (Fig. 3) provides a basis for analyzing road
Effects Of Incorrect Fluid Level test results.
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid Gearshift Lever Position
pressures to be low and develop slower than normal. DRIVE
P R N D 2 1
If the transmission is overfilled, the gears churn ELEMENTS 1 2 3 1 2
the fluid into foam. This aerates the fluid causing
the same conditions that occur with a low level. FRONT • •
CLUTCH
In either case, air bubbles cause fluid overheating,
oxidation and varnish buildup which interferes with FRONT
valve, clutch and servo operation. Foaming also BAND • •
(KICKDOWN)
causes fluid expansion which can result in fluid over
flow from the transmission vent or fill tube. Fluid REAR
CLUTCH
overflow can easily be mistaken for a leak if inspec
tion is not careful. REAR
BAND • •
(LOW-REV.)
TRANSMISSION THROTTLE CABLE ADJUSTMENT
Throttle cable adjustment is important to proper OVER
operation. This adjustment positions the throttle RUNNING • •
CLUTCH
valve which controls shift speed, quality and part
throttle downshift sensitivity.
J9021-33
If cable adjustment setting is too short, early shifts
and slippage between shifts may occur. If the setting Fig. 3 Clutch And Band Application Chart
is too long, shifts may be delayed and part throttle
downshifts may be very sensitive. Refer to the In-Ve ANALYZING THE ROAD TEST
hicle Service section for adjustment procedure. Refer to the Clutch and Band Application chart
(Fig. 3) and note which elements are in use in the
GEARSHIFT LINKAGE various gear ranges.
Gearshift linkage adjustment is important because The rear clutch is applied in all forward ranges (D,
it positions the valve body manual valve. Incorrect 2, 1). The overrunning clutch is applied in first gear
adjustment will cause creeping in Neutral, prema (D and 2 range only). The rear band is applied in 1
ture clutch wear, delayed engagement in any gear, or and R range only.
a no-start in Park or Neutral position. For example: If slippage occurs in first gear in D
Proper operation of the neutral start switch will and 2 range but not in 1 range, the overrunning
provide a quick check of linkage adjustment. Refer to clutch is slipping. Similarly, if slippage occurs in any
the In-Vehicle Service section for adjustment proce two forward gears, the rear clutch is slipping.
dure. Applying the same method of analysis, note that
both clutches are applied in D range third gear only.
ROAD TEST If the transmission slips in third gear, either the
Before road testing, be sure the fluid level and all front clutch or the rear clutch is slipping. By select
linkage adjustments have been checked and adjusted ing another gear which does not use one of these
if necessary. units, the slipping clutch can be determined.
Observe engine performance during the road test. Although road test analysis will help determine
A poorly tuned engine will not allow an accurate the slipping unit, the actual cause of a malfunction
analysis of transmission operation. may not be determined until hydraulic and air pres-
sure tests are performed. Practically any condition PRESSURE TEST PROCEDURE
can be caused by leaking hydraulic circuits or stick Connect a tachometer to the engine. Position the
ing valves. Unless the problem is an obvious one, do tachometer so it can be observed from under the ve
not remove and disassemble the transmission until hicle. Raise the vehicle on hoist that will allow the
hydraulic and air pressure tests have been per wheels to rotate freely.
formed.
Test One-Transmission In 1 Range
HYDRAULIC PRESSURE TEST This test checks pump output, pressure regula
Hydraulic test pressures range from a low of one tion, and condition of the rear clutch and rear
psi (6.895 kPa) governor pressure, to 300 psi (2068.5 servo circuits. Use 300 psi Test Gauge C3293 for
kPa) at the rear servo pressure port in reverse. this test
Use 100 psi Pressure Gauge C-3292 to check pres (1) Connect test gauges to line pressure and rear
sure at the accumulator, front servo, governor and servo ports (Figs. 4-5). Be sure pressure test gauge
fluid cooler line. Use 300 psi Gauge C-3293 to check is connected to rear servo port.
pressure at the rear servo. The 300 psi gauge can be (2) Disconnect throttle and gearshift rods at trans
used at any other port when more than one gauge is mission.
required for testing. (3) Start and run engine at 1000 rpm.
(4) Move valve body selector lever forward into 1
PRESSURE TEST PORT LOCATIONS range.
There are pressure test ports at the accumulator, (5) Read pressures on both gauges as transmission
front servo, rear servo and governor. throttle lever is moved from full forward to full rear
Line pressure is checked at the accumulator port ward position.
on the right side of the case (Fig. 4). The front servo (6) Line pressure should be 54-60 psi (372-414
release pressure port is at the right side of the case kPa) with throttle lever forward and gradually in
just behind the filler tube opening (Fig. 4). crease to 90-96 psi (620-662 kPa) as lever is moved
The rear servo pressure port is at the right rear of rearward.
the transmission case (Fig. 5). The governor pressure (7) Rear servo pressure should be same as line
port is at the left side of case at the transmission pressure within 3 psi.
rear (Fig. 5).
Test Two-Transmission In 2 Range
This test checks pump output and pressure
regulation. Use 100 psi Test Gauge C-3292 for
this test.
(1) Connect test gauge to line pressure port (Fig.
4).
(2) Start and run engine at 1000 rpm.
(3) Move valve body selector lever one detent rear
ward from full forward position. This is 2 range.
(4) Move transmission throttle lever from full for
ward to full rearward position and read pressure at
Fig. 4 Front Servo And Line Pressure Test Ports both gauges.
(5) Line pressure should be 54-60 psi (372-414
GOVERNOR
PRESSURE P O R T kPa) with throttle lever forward and gradually in
crease to 90-96 psi (620-662 kPa) as lever is moved
rearward.
Test Three-Transmission In D Range

This test checks pressure regulation and con
dition of the front and rear clutch circuits. Both
test gauges are required for this test.
(1) Connect one test gauge to line pressure port
and other gauge to front servo pressure port (Fig. 4).
Either gauge can be used at either port.
Fig. 5 Rear Servo And Governor Pressure Test (2) Start and run engine at 1600 rpm.
Ports (3) Move selector lever two detents rearward from
full forward position. This is D range.
21 - 7 2 32RH TRANSMISSION DIAGNOSIS J
(4) Read pressures on both gauges as transmission
TEST CONDITION INDICATION
throttle lever is moved from full forward to full rear
ward position. Line pressure O K during Pump and regulator valve O K
(5) Line pressure should be 54-60 psi (372-414 any one test
kPa) with throttle lever forward and gradually in
Line Pressure O K in R Leakage in rear dutch area (servo,
crease as lever is moved rearward. but low in D, 2 , 1 dutch seals, governor support
(6) Front servo is pressurized only in D range and seal rings)
should be same as line pressure within 3 psi (21 kPa)
Pressure O K in 1 , 2 but Leakage in front dutch area (servo,
up to downshift point. low in D3 and R dutch seals, retainer bore, pump
seal rings)
Test Four-Transmission In Reverse
Pressure O K in 2 but b w in Leakage in rear servo
T h i s test checks pump output, pressure regula
R and 1
tion and the front clutch and rear servo circuits.
Use 300 psi Pressure Test Gauge C-3293 for this Front servo pressure in 2 Leakage in servo; broken servo
test. ring or cracked servo piston
(1) Connect pressure test gauge to rear servo port Pressure b w in all positions Cogged filter, stuck pressure
(Fig. 5). regulator valve, worn or
(2) Start and run engine at 1600 rpm for test. defective pump
(3) Move valve body selector lever four detents Governor pressure too high at Governor valve sticking open
rearward from full forward position. This is Reverse idle speed:
range.
Governor pressure b w at all Governor valve sticking dosed
(4) Move throttle lever all way forward then all mph figures
the way rearward and note gauge readings.
(5) Pressure should be 145 - 175 psi (1000-1207 Lubrication pressure b w at all Cogged oil cooler or lines, seal
throttle positions rings leaking, output shaft
kPa) with lever forward and increase to 230 - 280 psi
plugged with debris, worn
(1586-1931 kPa) as lever is moved rearward. bushings in pump or dutch
retainer J9021-34
Test Five-Governor Pressure
T h i s test checks governor operation by mea Fig. 6 Pressure Test Analysis Chart
suring governor pressure response to changes i n
engine speed. I t i s usually not necessary to test checks the holding ability of the converter over
check governor operation unless shift speeds running clutch and both of the transmission clutches.
are incorrect or i f the transmission w i l l not shift When stall testing is completed, refer to the Stall
up or down. Use 1 0 0 psi Pressure Test Gauge Speed Specifications chart and Stall Speed Diagnosis
C-3292 for this test. guides.
(1) Connect test gauge to governor pressure port
(Fig. 5). WARNING: NEVER ALLOW ANYONE TO STAND
(2) Move selector lever to D range. IN FRONT OF THE VEHICLE DURING A STALL
(3) Apply service brakes. Start and run engine at TEST. A L W A Y S B L O C K THE FRONT WHEELS A N D
curb idle speed and note pressure. At idle and with APPLY THE SERVICE AND PARKING BRAKES
wheels stopped, pressure should be zero to 1-1/2 psi DURING THE TEST.
maximum. I f pressure exceeds this figure, governor
valve or weights are sticking open.
(4) Slowly increase engine speed and observe STALL TEST PROCEDURE
speedometer and pressure test gauge. Governor pres (1) Connect tachometer to engine.
sure should increase in proportion to vehicle speed (2) Check and adjust transmission fluid level.
(approximately 1 psi for every 1 mph shown on (3) Start and run engine until transmission fluid
speedometer). reaches normal operating temperature.
(5) Governor pressure rise should be smooth and (4) Block front wheels.
drop back to 0 to 1-1/2 psi when throttle is closed and (5) Fully apply service and parking brakes.
wheels are stopped. (6) Open throttle completely for no more than five
(6) Compare results of pressure tests with analysis seconds and record maximum engine rpm registered
chart (Fig. 6). , on tachometer.
CONVERTER STALL TEST

Stall testing involves determining maximum en
gine rpm obtainable at full throttle with the rear
wheels locked and the transmission in D range. This
CAUTION: Stall testing causes a rapid increase in FRONT SERVO APPLY^ FRONT
transmission fluid temperature. Do not hold the REAR SERVO A P P L Y SERVO
throttle open any longer than five seconds. If more
than one stall test i s required, run the engine at
1000 rpm with the transmission in Neutral f o r at LINE PRESSURE TO:
least 20 seconds to cool the fluid. ACCUMULATOR
(7) If engine speed exceeds maximum shown in

stall speed chart, release accelerator immediately.
This indicates that transmission clutch slippage is FRONT
CLUTCH
occurring. APPLY
(8) Shift transmission into Neutral. Run engine for REAR
20 seconds to cool fluid. Then stop engine, shift CLUTCH
transmission into Park and release brakes. APPLY
(9) Stall speeds should be in 1700-2000 rpm range. TO TORQUE

(10) Refer to Stall Test Diagnosis. GOVERNOR CONVERTOR
PRESSURE /
FROM TORQUE
STALL TEST DIAGNOSIS CONVERTER
TO
GOVERNOR T O COOLER ^H252
Stall Speed Too High
If the stall speed exceeds specifications by more Fig. 7 Air Pressure Test Passages
than 200 rpm, transmission clutch slippage is indi
cated. Air Test Procedure
(1) Place one or two fingers on the clutch housing
Stall Speed Too Low and apply air pressure through front clutch apply
Low stall speeds with a properly tuned engine in passage (Fig. 7). Piston movement can be felt and a
dicate a torque converter overrunning clutch prob soft thud heard as the clutch applies.
lem. The condition should be confirmed by road (2) Place one or two fingers on the clutch housing
testing prior to converter replacement. and apply air pressure through rear clutch apply pas
The converter overrunning clutch is slipping when sage (Fig. 7). Piston movement can be felt and a soft
stall speeds are 250 to 350 rpm below specified min thud heard as the clutch applies.
imum. And when the vehicle operates properly at (3) Apply air pressure to the front servo apply pas
highway speeds but has poor low speed acceleration. sage. The servo rod should extend and cause the
band to tighten around the drum. Spring tension
Stall Speed Normal should release the servo when air pressure is re
If stall speeds are normal but abnormal throttle moved.
opening is required to maintain highway speeds, the (4) Apply air pressure to the rear servo apply pas
converter overrunning clutch is seized and the torque sage. The servo rod should extend and cause the
converter must be replaced. band to tighten around the drum. Spring tension
should release the servo when air pressure is re
Converter Noise During Test moved.
A whining noise caused by fluid flow is normal
during a stall test. However, loud metallic noises in CONVERTER HOUSING LEAK DIAGNOSIS
dicate a damaged converter. To confirm that noise is Two items must be established when diagnosing
originating from the converter, operate the vehicle at leaks from the converter housing area. First, it must
light throttle in Drive and Neutral on a hoist and lis be verified that a leak condition actually exists. And
ten for noise coming from the converter housing. second, the true source of the leak must be deter
mined.
AIR PRESSURE TEST Some suspected converter housing fluid leaks may
Air pressure testing can be used to check clutch not be leaks at all. Residual fluid in the housing, or
and band operation with the transmission either in excess fluid spilled during factory fill or refill after
the vehicle, or on the work bench as a final check af repair can be mistaken for a leak. In addition, a rear
ter overhaul. main seal leak can also be mistaken for a pump seal
Air pressure testing requires that the oil pan and leak if care is exercised.
valve body be removed from the transmission.
The servo and clutch apply passages are shown in
Figure 7.
21 - 74 32RH TRANSMISSION DIAGNOSIS J
Converter housing leaks have several potential lever shaft access plug, pump bolts, or porous spots
sources. Through careful observation, a leak source in the pump body or transmission case (Fig. 10).
can be identified before removing the transmission (9) If porous spots in the transmission case or
for repair. pump body are the suspected leak source, pressurize
Pump seal leaks tend to move along the drive hub the transmission as described in Leak Testing With
and onto the rear of the converter. Pump O-ring or Air Pressure.
pump body leaks follow the same path as a seal leak
(Fig. 8).
Pump vent or pump attaching bolt leaks are gener
ally deposited on the inside of the converter housing
and not on the converter itself (Fig. 8).
Pump seal or gasket leaks usually travel down the
inside of the converter housing.
Front band lever pin plug leaks are generally de
posited on the housing and not on the converter.
A PUMP PUMP PUMP
SHIELD MATERIAL: 5-1/2" X 1-1/2" X 1/32"
BOLT S H E E T METAL RN778
Fig. 9 Leak Test Probe
Fig. 8 Typical Converter Housing Leak Paths

LEAK DIAGNOSIS PROCEDURE
(1) Raise the rear of the vehicle and allow accumu
lated fluid to drain out of the converter housing.
(2) Check and adjust the transmission fluid level.
Fig. 10 Pump Area Inspection Points
(3) Raise the vehicle. Remove the converter hous
ing dust cover and wipe as much fluid as possible LEAK TESTING WITH AIR PRESSURE
from the converter housing. This test involves closing off the transmission
(4) Fabricate a test probe (Fig. 9). Then attach the openings and pressurizing the transmission to 8 psi
probe to the converter housing with one of the dust with Air Pump Tool 7700.
shield bolts (Fig. 9). A soapy water solution is applied to suspected leak
(5) Have a helper run the engine at 2500 rpm points before and during the pressure test. Leaks will
(with the transmission in Neutral) for two minutes; be indicated by the presence of air bubbles coming
then stop the engine. through the solution.
(6) Inspect the test probe and converter housing. If Some transmission openings such as the fill tube
a leak is evident, note the color of the fluid. Trans and front cooler line fitting can be closed off with a
mission fluid is red. Engine oil ranges in color from rubber plug or similar device. Plugs can secured with
brown to green, or to black when the oil is dirty. wire or duct tape.
(7) If the probe upper surface is dry, the converter The transmission rear output shaft opening is
and seal are not at fault. A path of fluid across the closed off simply by leaving the transfer case bolted
probe upper surface indicates a converter or seal in place. However, if the transfer case has been re
leak. Fluid leaking under the probe is coming from moved, a shipping plug can used to close off this
the pump housing area (Fig. 10). opening.
(8) Fluid leaking under the probe could be from The torque converter hub opening in the pump and
the: pump seal and/or bushing, pump vent, kickdown the pump vent require special tools to close them off.
32RH TRANSMISSION DIAGNOSIS 21 - 75
The converter hub seal cap is made from thin wall 3/32" DRILL 2 H O L E S
tube and a 3 mm (1/8 in.) thick disc (Fig. 11). A re
taining strap is needed to secure the seal cup for
5/8"
testing. The strap can be made from 32 mm (1-1/4 WELD OR
in.) wide stock (Fig. 12). The strap attaching hole po BRAZE
sitions are approximate only. Measure hole position
on the converter housing before drilling.
The pump vent tool is made from 6 mm (1/4 in.) 3-3/4 4"
rod and 5 mm (3/16 in.) plate (Fig. 13). The fabri RADIUS
1/4" ROD
/
cated tools can all be made from mild steel or alumi
num stock.
WELD CHAMFER T U B E
O R BRAZE EDGE
CAP T O T U B E 1/16" M I N .
MATERIAL: 3/16 INCH S T E E L STOCK J9021-39
Fig. 13 Pump Vent Plug

(4) Apply thick soapy water solution to suspected
•1/8" CAP leak areas.
SEAL T H I S E N D POLISH T U B E
AIR TIGHT O.D. F O R CAUTION: T h e recommended test pressure i s 8
T H I S DISTANCE
psi. T h e maximum allowable test pressure i s 10 psi.
5"-6" K " 1-3/4"
Do not exceed specified test pressure.
(AS NEEDED) ~ * 1.495"-1.498" (999)
1.873"-1.876" (727)
(5) Pressurize transmission to 8 psi with air pump.
MAKE T O O L FROM: T H I N W A L L (6) Observe suspected leak areas. Air bubbles ap
T U B E A N D 1/8" THICK DISC
J9021-37 pearing in soapy water solution indicate leak points.
(7) Remove test tools and plugs after test comple
Fig. 11 Converter Hub Seal Cup tion and make necessary repairs as described in Leak
DRILL 4-5, 15/32" H O L E S Correction procedure.
AS NEEDED
V E N T PLUG
RETAINER
MAKE STRAP FROM: 1/4" x 1-1/4"

STOCK. HOLE LOCATIONS MAY
VARY. M E A S U R E BEFORE DRILLING. J9021-38
PLUG-MADE F R O M ^ s CONVERTER
SPRING OLD FILLER T U B E — H U B SEAL CUP J9021-40
Fig. 12 Seal Cup Retaining Strap
AIR PRESSURE LEAK TEST PROCEDURE Fig. 14 Vent Plug And Hub Seal Cup Installation
(1) Install vent plug, converter hub seal cup and CONVERTER HOUSING AREA LEAK
cup retaining strap (Fig. 14). CORRECTION
(2) Close off remaining transmission openings with (1) Remove converter.
rubber plugs, or stoppers. Do not close off rear (2) Tighten front band adjusting screw until band
cooler line fitting. Air pump will be attached to is tight around clutch retainer. This prevents
this fitting. clutches from coming out when oil pump is removed.
(3) Attach Air Pump 7700 to rear cooler line fit (3) Remove oil pump and seal. Inspect pump hous
ting. Connect length of copper tube to fitting. Then ing drainback and vent holes for obstructions. Clear
attach air pump hose to tube with hose clamp (Fig. holes with solvent and wire.
15). (4) Inspect pump bushing and converter hub. If
(5) Install new pump seal, O-ring, gasket, bushing.
Replace oil pump if cracked, porous or damaged in
any way.
(6) Loosen kickdown lever pin plug two turns. Ap
ply Permatex No. 2 or equivalent to plug threads and
tighten plug to 17 N»m (150 in-lbs) torque.
(7) Adjust front band.
(8) Lubricate pump seal and converter hub with
transmission fluid or petroleum jelly and install con
verter.
(9) Install transmission.
(10) Install converter housing dust shield and
lower vehicle.
DIAGNOSIS GUIDES AND CHARTS

The diagnosis charts provide additional reference
F i g . 15 Pressurizing Transmission for transmission diagnosis.
The hydraulic flow charts outline fluid flow and
bushing is scored, replace it. If converter hub is
hydraulic circuitry. Circuit operation is provided for
scored, either polish it with crocus cloth or replace
all gear ranges. Normal working pressures are also
converter if scoring is severe.
supplied for each of the various gear ranges.
32RH TRANSMISSION DIAGNOSIS
H A R S H E N G A G E M E N T (FROM 1. Engine idle speed too high 1. Check/adjust idle speed

N E U T R A L T O DRIVE O R
2 . Driver " r i d i n g " accelerator pedal during shift 2. Advise owner/operator
REVERSE)
3. Throttle cable or linkage misadjusted 3. Adjust cable or linkage; setting is either too
long or too short
4 . Band adjustment needed 4 . Adjust front/rear bands
5 . Loose mounting bolts 5. Check engine, transmission, propeller shaft,
crossmember, and axle bolt torque; tighten
loose bolts and replace missing bolts
6 W o r n or damaged U-joints 6 . Remove propeller shaft and replace U-joints
7. Loose axle pinion nut 7. Replace nut and check pinion threads before
installing new nut; replace pinion gear if
threads are damaged
8. Hydraulic pressure is incorrect 8. Check pressures; remove, overhaul, or adjust
valve body as needed; repair oil pump if
necessary
Note: The shift from neutral to
reverse is normally quite firm. 9 . Accumulator piston spring or seal worn or
/ 9 . Remove valve body and replace piston,
Hydraulic pressure at the rear damaged seal, or spring as needed
servo can approach 3 0 0 psi in
10. Faulty converter clutch (if equipped) 10. Replace converter and flush cooler and lines
reverse gear. Do not confuse a
before installing new converter
firm engagement with a truly
harsh engagement 11. Clutch, band, or planetary component is damaged 11. Remove, disassemble, and repair
transmission as necessary
DELAYED E N G A G E M E N T 1. Engine idle speed too low 1. Adjust idle speed

(FROM N E U T R A L T O D R I V E
OR REVERSE) 2. Low fluid level 2. Correct level and check for leaks
3. Gearshift linkage out of adjustment 3. Adjust cable or linkage and repair linkage if
worn or damaged
4 . Rear band out of adjustment 4 . Adjust band
5 . Valve body filter plugged 5 . Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary
6 . Oil pump gears worn or damaged or pump 6 . Remove transmission and replace oil pump
body or seal is damaged, allowing pump to
take in air, causing fluid aeration
7. Reaction shaft seal rings worn or broken 7. Remove transmission, remove oil pump, and
replace seal rings
8. Governor valve stuck or valve shaft is loose or 8. Remove and inspect governor components;
damaged replace worn or damaged parts
9 . Low hydraulic pressure 9 . Perform pressure test, remove transmission,
and repair as needed
10. Clutch, band, or servo damage 10. Remove and disassemble transmission and
repair as necessary
J9321-255
21 - 78 32RH TRANSMISSION DIAGNOSIS
J
Conditio® Possible Coose Correction
SHIFTS DELAYED OR ERRATIC 1. Low fluid level 1. Correct fluid level and check for leaks
(SHIFTS ALSO HARSH A T
2. Throttle linkage out of adjustment 2. Adjust linkage as described in service section
TIMES)
3. Throttle linkage is binding 3. Disassemble, clean, and adjust linkage; replace
linkage grommets if removed or if worn or
cracked
4. Gearshift linkage out of adjustment 4. Adjust linkage as described in service section
5. Fluid filter partially clogged 5. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary
6. Air in fluid due to overfill condition or air leakage 6. Drain fluid to correct level if overfilled. If fluid is
into pump suction passages highly aerated (full of bubbles and foamy), oil
pump gasket or seal may have failed, or pump
body is porous or cracked
7. Clutch or servo problem 7. Remove valve body and air test clutch, band and
servo operation; disassemble and repair
transmission as needed
8. Front band out of adjustment (may cause harsh 8. Adjust band
1-2 shift)
N O REVERSE (D RANGES OK) 1. Gearshift linkage is either out of adjustment or 1. Repair or replace linkage parts as needed
damaged
2. Rear band is out of adjustment 2. Adjust band
3. Valve body malfunction (stuck/damaged manual 3. Remove and service valve body; replace valve
valve, regulator valve, or check ball) body if any valves or valve bores are worn or
damaged
4. Rear servo or front clutch malfunction 4. Remove and disassemble transmission; replace
worn, damaged servo and clutch parts as
necessary
HAS FIRST-REVERSE ONLY 1. Governor valve, shaft, weights, or body damaged 1. Remove governor assembly and repair as
(NO 1-2 OR 2-3 UPSHIFT) necessary
J9121-440
€MI§f§#n C®RR®€FFIRA
N O DRIVE RANGE 1. Gearshift linkage either loose, damaged or out of 1. Repair or replace linkage components
(REVERSE OK) adjustment
2. Low fluid level 2. Correct fluid level and check for leaks
3. Valve body malfunction (manual valve or shaft 3. Remove and disassemble valve body; replace as
damaged or 1 -2 shift valve stuck) assembly if any valves or bores are damaged
4. Rear clutch failure 4. Remove and disassemble transmission and rear
clutch; repair/replace worn, damaged parts as
needed
5. Transmission overrunning clutch failure 5. Remove and disassemble transmission; replace
overrunning clutch
6. Input shaft seal rings worn or damaged 6. Remove and disassemble transmission; replace
seal rings and any other worn or damaged parts
N O DRIVE OR REVERSE 1. Low fluid level 1. Add fluid and check for leaks if drive is restored
(VEHICLE WILL N O T MOVE)
2. Gearshift linkage loose, damaged, or misassembled 2. Inspect, adjust, and reassemble linkage as needed;
replace worn, damaged parts
3. Failure of driveline component, such as U-joint, axle 3. Perform preliminary inspection procedure for
shaft, transfer case component, etc. vehicle that will not move; refer to procedure in
diagnosis section
4. Low fluid pressure due to worn or damaged oil 4. Perform pressure test to confirm low pressure;
pump replace pump body and/or gears if necessary
5. Transmission internal component damaged 5. Remove and disassemble transmission; repair or
replace failed components as needed
6. Valve body malfunction (seized valve, damaged 6. Remove, disassemble, and inspect valve body;
manual lever, valve body screws loose or replace valve body (as assembly) if any valve or
overtightened causing distortion and bind) bore is damaged; clean and reassemble correctly
if all parts are in good condition
J9121-443
Condition P o s s i b l e Cause Correction
MOVES IN 2 N D OR 3RD 1. Governor valve sticking 1. Remove, clean, and inspect; replace faulty parts
GEAR, ABRUPTLY
2. Valve body malfunction 2. Remove, clean, and inspect; look for stuck
DOWNSHIFTS T O L O W
1 -2 valve or governor plug
SUPS IN L O W GEAR D ONLY, 1. Overrunning clutch faulty, not holding 1. Replace overrunning clutch
BUT N O T IN 1 POSITION
SUPS IN FORWARD DRIVE 1. Low fluid level 1. Add fluid and check for leaks
RANGES
2. Air in fluid (fluid is foamy, full of bubbles), shifts are 2. Check for bad pump gasket or seals, dirt
spongy, caused by air getting into pump suction between pump halves, and loose pump bolts or
passages defective O-ring at filler tube
3. Gearshift or throttle linkage out of adjustment 3. Adjust linkage
4. Low hydraulic pressures due to worn pump, 4. Perform hydraulic and air pressure tests to
incorrect control pressure adjustments, valve body determine cause
warpage or malfunction, sticking governor, leaking
seal rings, clutch seals leaking, servo leaks, clogged
filter, or cooler lines
5. Accumulator piston cracked, spring broken or 5. Inspect and repair as necessary
seal worn
6. Clutch or servo malfunction, leaking seals or 6. Air pressure check clutch-servo operation and
worn plates repair as required
7. Overrunning clutch worn, not holding (slips in 7. Replace clutch
1 only)
SUPS IN REVERSE O I L Y 1. Low fluid level 1. Add fluid and check for leaks
2. Aerated fluid; see Slips in Forward Drive Ranges 2. See Slips in Forward Drive Ranges
3. Gearshift linkage out of adjustment 3. Adjust linkage
4. Rear band out of adjustment 4. Adjust band
5. Hydraulic pressure too low due to worn pump, worn 5. Perform hydraulic pressure tests to determine
seal rings, clutch or servo seal leakage cause
6. Worn front clutch, leaking rear servo, or worn 6. Air pressure check clutch-servo operation and
rear band repair as required
7. Band-linkage binding 7. Inspect and repair as required
J9121-444
NO KICKDOWN OR 1. Incorrect throttle linkage or cable adjustment 1. Adjust linkage or cable

NORMAL DOWNSHIFT
2 . Incorrect gear shift linkage or cable adjustment 2 . Adjust linkage or cable
3. Front band out of adjustment 3 . Adjust band
4 . Hydraulic pressures too high or too low due to 4 . Perform hydraulic pressure tests to determine
sticking governor, valve body malfunction, or cause ana repair as required. Correct valve
incorrect hydraulic control pressure adjustments body pressure adjustments as required
5 . Front servo, band, or linkage malfunction 5 . A i r pressure test operation and repair as
necessary
6 . Clutch or servo malfunction
6 . A i r pressure test operation and repair as
necessary
STUCK IN L O W GEAR (WILL 1. Gearshift or throttle linkage or cable out of 1. Adjust linkage or cable. Repair linkage of
NOT UPSHIFT) adjustment worn or damaged. Relace damaged cable.
2 . Front band out of adjustment 2 . Adjust band
3. Governor valve stuck closed; loose output shaft 3. Check line and governor pressures to
support or governor housing bolts, worn pump, determine cause; correct as required
leaking seal rings, or valve body problem (i.e.,
stuck 1-2 shift valve or governor plug)
4 . Clutch or servo malfunction 4 . Air pressure check operation of clutches and
bands; repair faulty component
N O L O W GEAR (MOVES IN 1. Governor valve sticking in partially open position 1. Remove governor; clean, inspect, and repair
2 N D O R 3 R D G E A R ONLY) as required
2 . Valve body malfunction 2 . Remove, clean, arid inspect. Look for sticking
1-2 valve, 2-3 valve, governor plug, or
broken springs
3. Front servo piston cocked in bore 3. Inspect servo and repair as required
4 . Front band linkage malfunction 4 . Inspect linkage and look for bind in linkage
5 . Incorrect throttle or gearshift linkage or cable 5 . Adjust linkage or cable
adjustment
J9321-256
CcwtditlM Possible C m s ® €#fr#€fl#§i
CREEPS IN NEUTRAL 1. Gearshift linkage out of adjustment 1. Adjust linkage

2. Valve body malfunction (warped body, cross 2. Perform hydraulic pressure test to determine
leakage) cause ana repair as required
3. Clutch dragging 3. Air pressure check operation of clutches and
repair as required
4. Converter lockup clutch dragging 4. Oil pump worn; replace pump
DRAGS O R LOCKS UP 1. Front or rear band out of adjustment 1. Adjust bands

2. Servo band or linkage malfunction (i.e., binding 2. Air pressure check servo operation and repair
linkage, warped band, servo piston stuck) as required
3. Air pressure check clutch operation and repair
3. Dragging clutch (does not release fully) as required
4. Remove, inspect, and repair as required (look
4. Broken or seized planetary gears for debris in oil pan)
5. Remove and inspect clutch, repair as required
5. Overrunning clutch worn, broken, or seized
GROWLING, GRATING, OR 1. Planetary gear set broken or seized 1. Check for debris in oil pan and repair as
SCRAPING NOISES required
2. Overrunning clutch worn, seized, or broken 2. Inspect and check for debris in oil pan; repair as
required
3. Oil pump components scored, binding, or broken 3. Remove, inspect, and repair as required
4. Output shaft bearing or bushing damaged 4. Remove, inspect, and repair as required
5. Faulty clutch operation 5. Perform air pressure check and repair as
required
6. Governor support (park gear) binding or seal rings 6. Remove, inspect, and repair as required
broken
7. Front and rear bands out of adjustment 7. Adjust bands
BUZZING NOISE 1. Low fluid level 1. Add fluid and check for leaks
2. Air being drawn into pump suction passages 2. Check pump for porous casting, scores on
mating surfaces, and excess rotor clearance;
repair as required
3. Overrunning clutch damaged 3. Replace clutch
4. Valve body misassembled, bolts loose, weak spring, 4. Remove, disassemble, inspect valve body;
or mispositioned valve or check ball reassemble correctly if necessary; replace
assembly if valves or springs are damaged
J9121-446
32RH TRANSMISSION DIAGNOSIS 21 - 83
Condition Possible Cnuse Correction
OIL COMES O U T FILLER TUBE 1. Transmission overfilled 1. Drain fluid to correct level; remove neutral
switch and drain through switch hole with
suction gun
2. Breather vent in oil pump blocked 2. Inspect and clear blockage
3. Fluid cooler or cooler lines plugged 3. Flush cooler and lines
4. Air in fluid (aerated) 4. See "Slips In Forward Drive Ranges"
5. Oil filter clogged 5. Replace filter; determine the reason for clogged
condition and repair
6. Rear servo piston or seal failure 6. Check hydraulic pressure at servo in reverse
(will register low or fluctuate rapidly)
7. Valve body switch valve sticking 7. Remove and clean valve
OIL LEAKS (ITEMS LISTED 1. Speedometer adapter 1. Replace both adapter seals
REPRESENT POSSIBLE LEAK
2. Pan gasket 2. Tighten pan screws to 150 inch-pounds; if
POINTS A N D SHOULD A l l BE
leaks persist, replace gasket; do not
CHECKED)
overtighten screws
3. Filler tube (where tube enters case) 3. Replace O-ring seal
4. Fluid lines and fittings 4. Tighten fittings; if leaks persist, replace fittings
and lines if necessary
5. Valve body manual lever shaft seal 5. Replace shaft seal
6. Pressure port plug loose 6. Tighten to correct torque; replace plug if leak
persists
7. Rear bearing access plate 7. Replace gasket
8. Gasket damaged or bolts are loose 8. Replace bolts or gasket or tighten bolts
9. Adapter/extension gasket damaged 9. Replace gasket
10. Neutral switch 10. Replace switch and gasket
11. Converter housing area 11. Check for leaks at seal caused by worn seal or
burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing, or hole plugged. Check for leaks past
O-ring seal on pump, or past pump-to-case
bolts; pump housing porous, oil coming out
vent due to overfill or leak past front band shaft
access plug
12. Cooler line fittings and hoses 12. Replace fittings and hoses
13. Pump seal 13. Replace seal
14. Torque converter 14. Replace converter
J9121-448
CeniliMM Possible Covse Correction
OVERHEAT DURING 1 . Vehicle not properly equipped for trailer towing or 1. Be sure vehicle is equipped with recommended
COMMERCIAL OPERATION commercial use optional components (i.e., HD springs,
OR WHILE TRAILER T O W I N G transmission, axle, larger CID engine, auxiliary
(FLUID DARK AND BURNED cooler, correct axle ratio, etc.). If vehicle is not so
W I T H SOME SLUDGE equipped, it should not be used for severe
FORMATION) service operation
2. Vehicle not equipped with auxiliary fluid cooler 2. Drain fluid, change filter, and install auxiliary
cooler
3. Extensive idling time or operation in heavy traffic in 3. Cut down on idling time; shift into neutral every
hot weather so often and run engine at 1000 rpm to help
circulate fluid through cooler
4. Tow vehicle overloaded (exceeding vehicle tow 4. Be sure vehicle is properly equipped to handle
capacity) load; do not tow Class Ill-type loads with a
vehicle that is only rated for Class 1 or II
operation
5. Air flow to auxiliary cooler blocked by snow plow, 5. Remove or reposition item causing air flow
front mounted spare tire, bug screen, or similar item blockage
OVERHEAT DURING NORMAL 1. Low fluid level 1. Add fluid and check for leaks
OPERATION (FLUID
2. Fluid cooler, lines blocked, or cooler cracked (oil in 2. Flush cooler and lines arid replace radiator if
DISCOLORED, SMELLS
engine coolant) transmission fluid has entered coolant
BURNED)
3. Switch valve sticking 3. Remove, disassemble, clean valve body
4. Clutch pack clearance incorrect (too tight) 4. Check and correct as required
5. Bands too tight 5. Adjust bands
J9121-450
Condition P o s s i b l e Cause Correction
NO START IN PARK OR 1. Gearshift linkage out of adjustment 1. Adjust linkage

NEUTRAL 2. Neutral switch wire broken or open 2. Check continuity with test lamp; repair as
required
3. Faulty neutral switch 3. Refer to service section for test and replacement
procedure
4. Valve body manual lever assembly bent, worn, 4. Inspect lever assembly and replace if damaged
broken, or not aligned with switch
SLUGGISH ACCELERATION A T 1. Poor engine performance 1. Check engine and repair as required
L O W SPEEDS OR REQUIRES 2. Adjust linkage
2. Gearshift or throttle linkage out of adjustment
EXCESSIVE THROTTLE
OPENING T O MAINTAIN 3. Transmission clutches slipping 3. Perform stall test and repair as required
HIGHWAY SPEEDS 4. Overrunning clutch in converter not holding 4. Perform stall test and replace converter if clutch
has failed
5. Converter overrunning clutch stuck 5. Replace converter
FLUID CONTAMINATED 1. If contamination occurred shortly after overhaul, 1. If contamination is severe, cooler flushing,
(DISCOLORED, FULL OF fluid cooler and lines were not flushed and flow converter replacement, and another overhaul
SLUDGE A N D / O R METAL tested. This is especially true when original overhaul may be necessary; particularly so if shift
AND FRICTION MATERIAL was to correct a problem that generated a large problems were also present
PARTICULAR) amount of debris, such as a gear failure or a clutch
pack failure
Note: Flushing the cooler and lines is mandatory after
a failure of the converter lockup clutch
2. Incorrect fluid used in transmission 2. If transmission is operating properly, drain fluid,
reverse flush cooler and lines, and change fluid
and filter. However, if shift problem has
developed, converter replacement and
transmission overhaul may be required
3. Main cooler in radiator is cracked, allowing engine 3. Replace radiator (and cooler) and flush lines. If
coolant to enter transmission problem was diagnosed early enough, fluid and
filter change may only be necessary. If
contamination periocl was prolonged, overhaul
and converter replacement may be required
4. Severe overload results in overheat, fluid break 4. Repair transmission, flush cooler, and lines.
down, and accelerated wear, especially in high Replace converter if necessary. Install auxiliary
ambient temperatures. Most frequent causes are: cooler if needed. Also install HD cooling system
if needed. If tow vehicle and unit being towed
• Vehicle is not properly equipped for heavy duty
are both overloaded, the only repair is to reduce
service
the load to rated limits. However, if trailer or
• Tow vehicle and boat or trailer are both boat is too large for tow vehicle, the only option
overloaded is for the owner to move up to properly-
• Trailer or boat are too large for tow vehicle (load equipped and load-rated tow vehicle
exceeds rated capacity of tow vehicle)
J9121-449
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PUMP S U C T I O N
SCREEN SELECTOR LEVER

IN PARK
ENGINE RUNNING
OIL FILTER
J9021-63
G O V E R N O R VALVE FRONT CLUTCH FRONT SERVO
ACCUMULATOR
TO
LUBRICATION
SELECTOR LEVER IN TORQUE CONVERTER

DRIVE (BREAKAWAY-1ST GEAR)
HALF THROTTLE
J9021-64
21 - 88 32RH TRANSMISSION DIAGNOSIS
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J9021-66
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LUBRICATION
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J9021-67
FRONT SERVO
ACCUMULATOR
TO
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SELECTOR LEVER IN
TWO (MANUAL SECOND) TORQUE CONVERTER
CLOSED THROTTLE J9021-69
G O V E R N O R VALVE REAR SERVO FRONT SERVO
F R O N T CLUTCH ACCUMULATOR
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TORQUE CONVERTER
J9021-71
J 32RH IN-VEHICLE SERVICE 21 - S i
32RH IN-VEHICLE SERVICE
INDEl
page page
Front Band Adjustment 96 Speedometer Service 102
Gearshift Linkage Adjustment . . . . . . . . . . . . . . . 95 Transmission Cooler Flow Testing . . . . . . . . . . . 101
Governor and Park Gear Service 99 Transmission Cooler Reverse Flushing . . . . . . . 101
Oil Filter Replacement 97 Transmission Throttle Cable Adjustment 96
Park Lock Component Replacement . . . . . . . . . 100 Valve Body Installation 98
Park/Neutral Position Switch Service 100 Valve Body Removal 97
Rear Band Adjustment . . . . . . . . . . . . . . . . . . . . 97 Valve Body Service 98
GEARSHIFT LINKAGE ADJUSTMENT 1). Tighten, repair, replace worn, damaged parts. Do
(1) Check linkage adjustment by starting engine in not attempt adjustment if linkage components are
Park and Neutral. worn or damaged.
(2) Adjustment is OK if engine starts only in park (7) Loosen shift rod trunnion lock bolt or nut. Be
and Neutral. Adjustment is incorrect if engine starts sure upper shift rod slides freely in trunnion (Fig. 1).
in one but not both positions. Also be sure shift rods and bellcrank rotate freely
(3) If engine starts in any position other than Park and do not bind at any point.
or Neutral, or if engine will not start at all, park/ (8) Verify that manual lever is in Park detent
neutral position switch may be faulty. (Fig. 1). Move lever all the way rearward to be sure
(4) Shift transmission into Park. it is in Park.
(5) Raise vehicle. ( 9 ) Check for positive engagement of park lock by
(6) Check condition of shift rods, bellcrank, bell- attempting to rotate propeller shaft. Shaft will not
crank brackets and linkage bushings/grommets (Fig. turn when park pawl is engaged.
Fig. 1 Gearshift Linkage

21 - 96 32RH IN-VEHICLE SERVICE
(10) Adjust shift rod trunnion to a obtain free pin THROTTLE CABLE ADJUSTMENT
J
fit in bellcrank arm and tighten trunnion lock bolt or PROCEDURE
nut. Prevent shift rod from turning while tightening Cable adjustment is performed entirely in the
bolt or nut. Gearshift linkage lash must be elimi engine compartment. It is not necessary to raise
nated to obtain proper adjustment. Eliminate lash by the vehicle for access to any other components.
pulling downward on shift rod and pressing upward (1) Shift transmission into Park and shut engine
on bellcrank. off.
(11) Confirm proper adjustment by starting engine (2) Press cable release button (Fig. 3).
in Park and Neutral. Engine should start in these (3) Push cable conduit back into cable adjuster
positions only. If engine starts in any position body as far as possible (Fig. 4).
other than Park or Neutral, adjustment is incor (4) Rotate throttle body lever to wide open throttle
rect or neutral switch is faulty. position. Cable will ratchet to correct adjustment
(12) Lower vehicle and verify that steering lock op point as lever is rotated (Fig. 4).
erates correctly.
FRONT BAND ADJUSTMENT
TRANSMISSION THROTTLE CABLE ADJUSTMENT The front band adjusting screw is located on the
A cable is used to control throttle pressure and left side of the transmission case above the manual
kickdown on 32RH transmissions (Fig. 2). valve and throttle valve levers.
Correct cable adjustment is important to proper op (1) Raise vehicle.
eration. The cable positions the throttle valve which (2) Loosen band adjusting screw locknut. Then
controls shift speed, shift quality and part throttle back locknut off 4-5 turns. Be sure adjusting screw
downshift sensitivity. If the setting is incorrect, shift turns freely in case.
#
quality and shift speeds will be unsatisfactory. (3) Tighten band adjusting screw to 8 N m (72 in.
lbs.) torque with inch-pound Torque Wrench
C-3380-A. If Adapter Extension C-3705 is needed
in order to reach adjusting screw, tighten screw
to only 5.3-5.6 N«m (47-50 in. lbs.) torque (Fig. 5).
(4) Back off band adjusting screw 2-1/2 turns.
KICKDOWN KICKDOWN TRANSMISSION
CABLE ACCELERATOR CABLE CABLE THROTTLE
LEVER
CABLE
ENGINE
BRACKET
J9121-370
Fig. 2 Transmission Throttle Cable—YJ

J 32RH IN-VEHICLE SERVICE 21 - 97
CONDUIT RELEASE REAR BAND ADJUSTMENT

The transmission oil pan must be removed for ac
cess to the rear (low-reverse) band adjusting screw.
(1) Raise vehicle.
(2) Remove transmission oil pan and drain fluid.
(3) Loosen band adjusting screw locknut 5-6 turns.
Be sure adjusting screw turns freely in lever.
(4) Tighten adjusting screw to 8 N»m (72 in. lbs.)
torque (Fig. 6).
(5) Back off adjusting screw four turns.
(6) Hold adjusting screw in place and tighten lock-
nut to 34 N*m (25 ft. lbs.) torque.
(7) Position new gasket on oil pan and install pan
#
on transmission. Tighten pan bolts to 17 N m (150
in. lbs.) torque.
Fig. 3 Throttle Cable Components (8) Lower vehicle and refill transmission with rec
ommended fluid.
Fig. 6 Rear Band Adjustment Screw Location

Fig. 4 Throttle Cable Adjustment
OIL FILTER REPLACEMENT
(5) Hold adjuster screw in position and tighten
(1) Raise vehicle.
locknut to 41 N»m (30 ft. lbs.) torque.
(2) Remove oil pan and drain fluid.
(6) Lower vehicle. (3) Remove filter screws and remove oil filter (Fig.
7).
(4) Position new filter on valve body and install fil
ter screws finger tight.
#
(5) Tighten filter screws to 4 N m (35 in. lbs.) with
inch pound torque wrench.
(6) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 17 N»m (150
in. lbs.) torque.
(7) Lower vehicle.
(8) Refill transmission with Mopar ATF Plus, Type
7176. Mopar Dexron II can be used if ATF Plus is
not readily available.
VALVE BODY REMOVAL

(1) Raise vehicle.
(2) Remove oil pan and drain fluid.
(3) Disconnect gearshift and throttle linkage at
Fig. 5 Typical Front Band Adjustment
transmission levers.
(4) Loosen clamp bolts and remove throttle and
manual valve levers from manual valve shaft.
21 - 98 32RH IN-VEHICLE SERVICE
OIL
FILTER
A N D SHAFT LEVER A S S E M B L Y
PUS
Fig. 9 Valve Body Assembly

J8921-375 The remaining valve body components are serviced
only as part of a complete valve body assembly.
Fig. 7 Oil Filter Removal/Installation
(5) Disconnect park/neutral position switch wires VALVE BODY INSTALLATION
and remove switch and switch seal. (1) Place valve body manual lever in low (1 posi
(6) Remove valve body oil filter. tion) so park lock rod can be installed in sprag.
(7) Remove valve body attaching screws. Lower (2) Position park sprag with screwdriver to ease
valve body slightly and remove accumulator piston lock rod installation and engagement.
and spring (Fig. 8). Rotate valve body down and (3) Install new seals on accumulator piston if nec
away from case. Pull it forward to disengage park essary and install piston in case. A small amount of
rod and remove valve body. petroleum jelly can be used to hold piston in place.
(8) Position valve body on bench or on repair stand (4) Lubricate shaft of manual lever and lip of shaft
for disassembly, cleaning and inspection (Fig. 9). seal with petroleum jelly.
(5) Raise valve body and align park rod with case
opening and park sprag. Then push rod end through
opening and past sprag. Rotate propeller shaft if nec
essary.
(6) Position accumulator spring on transfer plate.
(7) Align valve body and seat it on case. Be sure
manual lever shaft and accumulator spring are prop
erly seated.
(8) Hold valve body in position and install one or
Fig. 8 Accumulator Piston And Spring two attaching bolts to hold valve body in place.
VALVE BODY SERVICE (9) Install remaining valve body bolts. Tighten all
The valve body can be disassembled for cleaning bolts evenly in a diagonal pattern to 12 N»m (105 in-
and inspection of the individual components. Valve lbs) torque.
body service procedures are detailed in the overhaul (10) Install new oil filter and tighten filter screws
section. to 4 N*m (35 in. lbs.) torque.
The only serviceable valve body components are: (11) Install manual and throttle levers on throttle
• park lock rod and E-clip lever shaft. Tighten lever clamp screws and check for
• switch valve and spring free operation. Shaft and levers must operate freely
• pressure adjusting screw bracket without any bind.
• throttle valve lever (12) Install oil pan and new gasket. Tighten pan
• manual lever bolts to 17 N-m (13 ft. lbs.) torque.
• manual lever shaft seal, washer, E-clip and detent (13) Install seal on neutral switch, install switch
ball in case, and connect switch wires.
• fluid filter. (14) Lower vehicle.
32RH IN-VEHICLE SERVICE 21 - 99
J (15) Fill transmission with Mopar ATF Plus, Type (2) Remove snap ring and separate inner weight
7176, or with Mopar Dexron II® fluid. and outer weight and spring (Fig 11).
(16) Adjust gearshift linkage and throttle valve (3) Remove bolts attaching governor to park gear
(kickdown) cable if necessary. (Fig. 11).
(4) Remove park gear from governor body.
GOVERNOR AND PARK GEAR SERVICE (5) Remove filter screen from park gear or gover
nor body (Fig. 11).
GOVERNOR REMOVAL
(1) Raise vehicle. SPRING
(2) Mark both propeller shaft yokes for assembly OUTER WEIGHT
reference and disconnect propeller shafts at transfer
case.
(3) Disconnect speedometer cable. VALVE, S H A F T
SNAP'
(4) Position support stand under transmission con RINGS VALVE
verter housing.
(5) Remove rear crossmember. INNER W E I G H T
SNAP
(6) Disconnect parking brake cable at equalizer RING
and disconnect exhaust pipe support brackets, if nec
essary.
FILTER SCREEN
(7) Support transfer case with jack.
(8) Remove bolts attaching transfer case to trans
mission adapter housing and remove transfer case.
(9) Remove bolts attaching adapter housing to
transmission and remove adapter housing.
(10) Rotate transmission output shaft until gover
nor snap rings face downward (Fig. 10). GOVERNOR
(11) Remove E-clip from one end of governor valve VALVE
shaft (Fig. 10). SPOTFACE J9221-51
(12) Remove governor valve and shaft from gover
nor body. Fig. 11 Governor Components
(13) Remove snap ring that retains governor body-
park gear assembly on output shaft (Fig. 10). CLEANING AND INSPECTION
(14) Remove governor body-park gear assembly Thoroughly clean all the governor parts in a suit
from output shaft. able cleaning solution but do not use any type of
caustic cleaning agents.
GOVERNOR S U P P O R T The weights and valves should fall freely in their
A N D P A R K I N G GEAR
bores when clean and dry. Minor surface scratches
and burrs can be removed with crocus cloth.
Inspect the governor weight spring for distortion.
Replace the spring, if damaged. Clean the filter in
solvent and dry it with compressed air. Replace the
filter, if damaged. Inspect the park gear for chipped
or worn gear teeth or damaged ring grooves. Replace
the gear, if damaged.
GOVERNOR ASSEMBLY
GOVERNOR BODY The governor valve used in 1992-93 transmis
sions is now made of aluminum. In addition, the
LOCKING BOLTS (4) output shaft has been spotfaced to accept the
new aluminum valve. The aluminum valve must
RH269 not be used in previous 32RH transmissions. The
valve can only be used with an output shaft that
Fig. 10 Governor E-clips And Attaching Bolts has been spotfaced for valve end clearance. In
GOVERNOR DISASSEMBLY addition, the governor body and output shaft
(1) Remove governor weights and spring from body must be properly indexed during reassembly. Be
(Fig. 11).
21 - 100 32RH IN-VEHICLE SERVICE J
sure to index these components as described in ADAPTOR SPRAG

the Transmission Assembly and Adjustment pro
cedures.
(1) Install filter screen in park gear.
(2) Assemble governor body and park gear. Be sure
oil passages in body and gear are aligned.
(3) Install governor-to-park gear bolts finger tight
only at this time.
(4) Install governor weight snap ring in governor
body. Then install governor weight and spring as
sembly in governor body.
GOVERNOR INSTALLATION
(1) Align and install park gear/governor assembly
on output shaft. ASSEMBLY RING ROD J9021-51
(2) Align valve shaft bore in governor body with
Fig. 12 Park Lock Components
bore in output shaft. Be sure hole in output shaft
for governor valve shaft is aligned with gover sprag for broken edges. Check the lugs on the gover
nor valve bore in governor body. Valve shaft nor support (park gear) for broken edges.
will bind if misalignment occurs. Remove and Check the knob on the end of the control rod for
reposition governor body if necessary. nicks, burrs and free turning.
(3) Install governor valve and shaft. Be sure shaft Replace any park lock components that are worn or
slides freely in bore before installing E-clip on shaft. damaged.
(4) Install governor valve on shaft and in governor The park lock rod used in Chrysler 3-speed, rear
drive transmissions are different lengths (Fig. 12). If
body. Then install second shaft retaining snap ring.
the rod must be replaced, be sure to install the cor
(5) Install snap ring that retains governor on out
rect length and shape rod.
put shaft (Fig. 24).
(6) Tighten governor-to-park gear bolts to 11 N-m COMPONENT INSTALLATION
(95 in. lbs.). (1) Install park lock rod on valve body.
(7) Install adapter and gasket on transmission. (2) Install reaction plug and pin assembly in the
Tighten adapter bolts to 32 N-m (24 ft. lbs.). housing and install the snap ring.
(8) Install transfer case and rear crossmember. (3) Position sprag and spring in housing and in
(9) Connect speedometer cable, or vehicle speed stall sprag shaft. Be sure square lug on sprag is fac
sensor wires exhaust pipe brackets and brake cable, ing park gear and that spring is positioned so it
if removed. moves sprag away from park gear.
(10) Align and connect propeller shafts. Tighten (4) Install valve body.
clamp bolts to 19 N-m (14 ft. lbs.) torque. (5) Install adapter housing and transfer case.
(11) Remove supports and lower vehicle.
(12) Check and adjust transmission fluid level. PARK/NEUTRAL POSITION SWITCH SERVICE
The starter feed circuit of the switch is through the
PARK LOCK COMPONENT REPLACEMENT switch center terminal (Fig. 13). It provides a ground
for the starter solenoid circuit through the gearshift
COMPONENT REMOVAL lever in park and neutral only.
(1) Raise vehicle and remove transfer case and The two outer terminals of the park/neutral posi
adapter housing from transmission. tion switch are for the backup lamp switch circuit.
(2) Slide sprag shaft out of adapter housing and re
move park sprag and spring (Fig. 12). SWITCH TEST PROCEDURE
(3) Remove snap ring and slide plug and pin as (1) Remove wiring connector from switch.
sembly out of housing (Fig. 12). (2) Test continuity between switch center terminal
(4) If park rod must be serviced, remove valve and transmission case. Continuity should exist only
body and remove rod. when transmission is in Park or Neutral. Replace
switch if continuity occurs in any gear other than
Inspection 1
Park or Neutral.
Check the sprag shaft for scores and for free move (3) Shift into reverse and test continuity between
ment in the housing and sprag. two outside terminals on switch. Continuity should
Check the sprag and control rod springs for loss of exist only when transmission is in reverse.
tension or distortion. Check the square lug on the (4) Leave transmission in reverse and test continu-
J 32RH IN-VEHICLE SERVICE 21 - 101
reverse flushing. However, reverse flushing can be

performed using hand operated equipment as de
scribed in the following procedure.
REVERSE FLUSHING PROCEDURE

(1) Disconnect cooler lines at transmission. Refer
to Figure 14 for cooler line fitting identification.
Front fitting is outlet to cooler and rear fitting is in
let from cooler.
Fig. 13 Park/Neutral Position Switch And Manual

Lever
ity between each switch outer terminal and trans (TO COOLER) J9121-356
mission case. Continuity should not exist between
either pin and case in reverse. Fig. 14 Identifying 32RH Transmission Cooler
(5) If switch tests OK, check gearshift linkage ad Fittings
justment or backup light circuit. Replace switch if it (2) Position drain pan under cooler outlet line to
fails continuity tests. material flushed through cooler and lines.
(3) Reverse flush cooler using hand operated suc
SWITCH REPLACEMENT
tion gun filled with mineral spirits. Insert gun nozzle
(1) Position drain pan under neutral switch.
(or hose) into cooler inlet (return) line. Then force
(2) Disconnect switch wires.
mineral spirits through Line and cooler.
(3) Remove switch from transmission. (4) Continue reverse flushing until fluid exiting in
(4) Move shift lever to Park and Neutral positions. let (pressure) line is clear and free of debris/residue.
Inspect manual lever fingers, lever and shaft for Replace radiator if fluid cannot be pumped
proper alignment with switch opening in case. Re through cooler.
place lever if worn or bent. Do not attempt to (5) Clear flushing materials from cooler and lines
straighten the lever. with short pulses of compressed air. Insert air gun
(5) Install new switch and seal in case. Tighten nozzle into cooler inlet (return) line and continue
switch to 33 N*m (24 ft. lbs.) torque. short pulses of air until all fluid is cleared from
(6) Adjust transmission fluid level as required. cooler and lines.
(7) Verify switch operation. (6) Pump one quart of fresh automatic transmis
sion fluid through cooler and lines before reconnect
TRANSMISSION COOLER REVERSE FLUSHING ing cooler lines.
The transmission main cooler is located in the ra
diator lower tank. The cooler is not a serviceable TRANSMISSION COOLER FLOW TESTING
component. If the cooler is damaged in any way, the The transmission main and auxiliary coolers
radiator will have to be replaced. should be flow tested whenever a fluid overheat con
Some models may be equipped with an auxiliary dition is suspected. An overheat condition is indi
cooler. The cooler is mounted in front of the radiator cated when the fluid changes from the normal red, to
or air conditioning condenser. The auxiliary cooler is a dark orange, or brown color.
a serviceable component and can be repaired if nec The same method of flow testing is used for both
essary. coolers.
The main and auxiliary coolers should be thor Cooler flow is checked by measuring the amount of
oughly reverse flushed if a transmission failure fluid flow through the cooler in a 20 second time pe
contaminates the fluid. Reverse flushing the riod. The test is performed with the engine running
cooler and lines will prevent sludge and parti and transmission in neutral. Fluid is then pumped
cles from flowing back into the transmission af through the cooler by the transmission oil pump.
ter repair. (1) Disconnect cooler inlet line at transmission fit
The same flushing procedure is used for main and ting.
auxiliary coolers. Pressure equipment is preferred for (2) Securely attach hose to end of inlet line and po-
21 - 102 32RH IN-VEHICLE SERVICE J
sition line in a one quart test container. (12) Install vehicle speed sensor in sensor adapter.
(3) Add extra quart of fluid to transmission. Tighten sensor attaching bolt to 5-8 N»m (48-72 in.
(4) Use stopwatch to check flow test time. lbs.) torque.
(5) Shift transmission into neutral and set parking (13) Connect wires to vehicle speed sensor.
brake. (14) Lower vehicle.
(6) Start and run engine at curb idle speed and im (15) Check and adjust transmission fluid level if
mediately note cooler flow. Approximately one quart necessary.
of fluid should flow into test container in 20 second
period.
SPEEDOMETER
(7) If cooler flow is intermittent, flows less than PINION
one quart in 20 seconds, or does not flow at all, ADAPTER
cooler is faulty and must be replaced. O-RING
SPEEDOMETER
SPEEDOMETER SERVICE ADAPTER
SPEEDOMETER COMPONENT REMOVAL

(1) Raise vehicle.
(2) Disconnect vehicle speed sensor wires.
(3) Remove vehicle speed sensor and sensor SENSOR
ADAPTER
adapter from speedometer adapter (Fig. 15).
(4) Check speed sensor mounting area in speedom
eter adapter. If transmission fluid is found in this ADAPTER
area, adapter oil seal is leaking and will have to be CLAMP
replaced.
(5) Remove bolt and clamp securing speedometer SEAL
adapter transfer case (Fig. 15). RETAINER
RING
(6) Carefully work speedometer adapter and pinion VEHICLE
out of transfer case. SPEED
SENSOR
J9321-258
SPEEDOMETER COMPONENT INSTALLATION
(1) Replace adapter O-ring if cut, or worn. Fig. 15 Speedometer Components—YJ
(2) Replace speedometer adapter oil seal if neces
sary. Remove old seal and start new one in adapter ADAPTER LOCK RING
by hand. Then press seal into adapter with Installer

Tool C-4004 until tool bottoms (Fig. 16).
(3) Thoroughly clean speedometer adapter flange
and adapter mounting surface in transmission
adapter housing. These surfaces must be clean for
proper alignment and operation. TOOL
(4) Lubricate adapter oil seal and O-ring with OIL SEAL
RH263
transmission fluid.
(5) Count number of teeth on speedometer pinion Fig. 16 Replacing Speedometer Adapter Oil Seal
before installing pinion in adapter.
(6) Note range index numbers on speedometer
adapter face (Fig. 17). These numbers correspond to
number of teeth on pinion.
(7) Install speedometer adapter in transfer case.
(8) Rotate speedometer adapter until required
range numbers are at six o-clock position (Fig. 17).
Be sure range numbers correspond to number of
teeth on pinion.
(9) Lightly push speedometer adapter into transfer
ADAPTER
case until seated.
6 O'CLOCK POSITION RH260
(10) Install adapter clamp. Tighten clamp bolt to
11 N*m (100 in. lbs.) torque.
Fig. 17 Indexing Speedometer Adapter
(11) Install vehicle speed sensor adapter on speed
ometer adapter. Tighten sensor adapter coupling nut
to 17 N*m (150 in. lbs.) torque.
J 32RH TRANSMISSION REMOVAL AND INSTALLATION 21-103
32RH TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
Converter—Pump Seal—Drive Plate Service . . . 103 Transmission and Converter Removal . 103
Transmission and Converter Installation 104
TRANSMISSION AND CONVERTER REMOVAL ITEM TORQUE

(1) Remove fan shroud attaching bolts. A 4 1 - 6 8 N-m (30-50 ft. lbs.)
(2) Disconnect transmission fill tube at upper
bracket.
(3) Raise vehicle.
(4) Remove inspection cover from converter hous
ing and remove skid plate for access, if necessary.
(5) Remove transmission fill tube and fill tube TORQUE
ARM
O-ring. BRACKET
(6) Remove starter motor.
(7) Mark propeller shafts and axle yokes for align
ment reference. CUSHION
(8) Disconnect propeller shafts at transfer case
yokes. Secure shafts to frame rails with wire.
(9) Disconnect exhaust pipes at exhaust manifolds,
if necessary.
(10) Drain transfer case lubricant.
(12) Disconnect transfer case shift linkage.
(13) Disconnect gearshift and throttle linkage at
transmission.
(14) Disconnect park/neutral position switch wires.
(15) Disconnect and remove crankshaft position SKID
sensor. Retain sensor bolt for reinstallation. PLATE
CAUTION: T h e crankshaft position sensor can be

J9321-260
damaged during transmission removal (or installa
tion) if the sensor i s still bolted to the engine block. Fig. 1 Transmission Rear Mount
T o avoid damage, remove the sensor before remov
ing the transmission. (24) Move transmission and converter rearward
until clear of crankshaft.
(16) Remove converter housing access cover and (25) Hold converter in position and lower transmis
mark drive plate and converter for alignment refer sion until converter housing clears engine.
ence. (26) Remove converter from transmission.
(17) Remove bolts attaching converter to drive (27) Remove transfer case from transmission.
plate. (28) If necessary, following components can now be
(18) Support engine with support stand. serviced:
(19) Support transmission-transfer case assembly torque converter
with transmission jack. Secure transmission to jack torque converter drive plate
with safety chain. oil pump seal
(20) Remove bolts/nuts attaching cushion and engine rear core hole plugs
torque arm bracket to skid plate (Fig. 1). engine rear oil galley plugs
(21) Remove skid plate, or rear crossmember, if
equipped. CONVERTER-PUMP SEAL-DRIVE PLATE
(22) Lower transmission slightly and disconnect SERVICE
cooler lines at transmission. The drive plate and torque converter can be re
(23) Remove bolts attaching transmission to en placed or removed for service access after the trans
gine. mission has been removed (Fig. 2).
21 - 104 32RH TRANSMISSION REMOVAL AND INSTALLATION J
The torque converter is not a serviceable part. If

the converter is contaminated or damaged in any
way, it must be replaced as an assembly. Do not at
tempt to flush a converter contaminated by
metal or clutch facing particles. Flushing will
not remove these contaminants.
A new torque converter and oil pump are used
in 1993, 32RH transmissions. The new converter
has a different style drive hub. The hub was
changed to accept the new design drive flats on SPECIAL
the oil pump inner gear. The drive flats replace TOOL
J9321-262 C-3981B
the square lugs used previously. If converter re
placement should become necessary, be sure to
Fig. 3 Pump Seal Removal
use the new style converter. The new converter
and oil pump are not interchangeable with pre PUMP
vious style parts. SEAL
DRIVE REINFORCEMENT TORQUE

PLATE PLATE CONVERTER
SPECIAL
TOOL
C-4193
(32RH/42RH)
OR
C-3860-A
(36RH/46RH)
J9321-180
Fig. 4 Pump Seal installation

TRANSMISSION AND CONVERTER INSTALLATION
CAUTION: T h e t r a n s m i s s i o n oil c o o l e r and lines
must b e r e v e r s e flushed if repair c o r r e c t e d a p r o b
lem that g e n e r a t e d s l u d g e and/or d e b r i s . S l u d g e
CONVERTER DRIVE PLATE and metal o r friction particles from a g e a r o r clutch
BOLT (4) BOLT (6) J8921-381
p a c k failure must b e r e m o v e d b e f o r e reinstalling
the transmission. T h i s is n e c e s s a r y t o a v o i d re-con
Fig. 2 Typical Converter And Drive Plate
taminating the repaired t r a n s m i s s i o n . Failure t o re
The oil pump seal is accessible and can be replaced m o v e s l u d g e o r d e b r i s from the c o o l e r and lines
after the transmission and torque converter are re will result in a repeat failure and s h o p c o m e b a c k .
moved.
Use Remover Tool C-3981B to remove the seal (1) Lubricate converter drive hub and pump seal
(Fig. 3). To use the tool, first start the tool into the with Mopar ATF Plus, or Dexron II transmission
seal by hand. Next, thread the tool into the seal as fluid. Then install converter. Turn converter back
far as it will go. Use a wrench on the tool hex to turn and forth to align drive slots in converter hub with
the tool. Continue tightening until all the tool pump gear lugs. Be sure converter is fully seated in
threads firmly grip the metal part of the seal. Then pump (Fig. 5).
tighten the tool puller screw to withdraw the seal (2) Temporarily secure converter with C-clamp or
from the pump body. metal strap attached across converter housing.
Use Installer Tool C-4193 to install and seat the (3) Position transmission on jack and secure it
seal (Fig. 4). with safety chains.
Be sure to lubricate the pump seal and con (4) Raise transmission and align converter with
verter hub with transmission fluid before instal drive plate.
lation.
J 32RH TRANSMISSION REMOVAL AND INSTALLATION 21-101
(7) Install and tighten converter attaching bolts.

(8) Install and tighten bolts that attach transmis
sion to engine (Fig. 6 ) .
(9) Install crankshaft position sensor as follows:
CAUTION: Clearance between the sensor pickup

face and driveplate ring gear must be correctly es
tablished before engine startup. A cardboard
spacer, attached to the sensor face, i s used for this
purpose. Failure to establish correct clearance will
result in sensor breakage.
(a) Remove any remaining fragments of original

cardboard spacer from sensor pickup face.
(b) Align and install new spacer on sensor
pickup face. Spacer has adhesive backing so it will
adhere to sensor face.
(c) Insert sensor into housing until it just
touches ring gear teeth. Then install and tighten
Fig. 5 Checking Torque Converter Seating sensor attaching bolt. Correct clearance is estab
(5) Move transmission forward. Then raise, lower lished when spacer is peeled off by ring gear dur
or tilt transmission to align converter housing with ing engine startup.
engine block dowels. (10) Install transmission fill tube and O-ring (Fig.
(6) Install two converter housing lower attaching 6).
bolts and tighten bolts to draw housing toward en
gine.
21 - 106 32RH TRANSMISSION REMOVAL AND INSTALLATION
(11) Connect transmission cooler lines. Refer to (16) Install inspection cover on converter housing.
Figure 8 for cooler line identification. (17) Install exhaust pipes and support brackets, if
removed.
(18) Install starter motor.
(19) Connect wires to park/neutral position switch.
(20) Connect gearshift and linkage and throttle ca
ble.
(21) Connect transfer case shift linkage.
(22) Connect propeller shafts to transfer case
yokes.
(23) Connect front exhaust pipes and catalytic con
verter support bracket bolts (if removed).
J9121-112 (24) Install skid plate, rear cushion and bracket, if
removed.
Fig. 8 Transmission Cooler Line Fitting Location (25) Fill transfer case to bottom edge of fill plug
(12) Position support stand under transmission and hole with Mopar ATF Plus, Type 7176, or Dexron II.
remove transmission jack. (26) Lower vehicle and fill transmission to correct
(13) Install transfer case on transmission adapter. level with ATF Plus, type 7176 fluid. Mopar Dexron
II can be used if ATF Plus is not readily available.
Tighten attaching nuts to 41 N*m (30 ft. lbs.) torque.
(27) Install fan shroud and bolts (if removed).
(14) Install rear crossmember and attach transmis
(28) Check and adjust gearshift linkage if neces
sion rear support to crossmember.
sary. Then check and adjust throttle cable if neces
(15) Connect vehicle speed sensor wires. sary.
32RH TRANSMISSION OVERHAUL 21 - 107
J
32RH TRANSMISSION OVERHAUL
INDEX
page page
Adapter Housing and Park Lock Component Planetary Gear Train—Output Shaft Overhaul . . 125
Overhaul 114 Rear Clutch Overhaul 122
Front Clutch Overhaul 120 Rear Servo and Band Overhaul . 130
Front Servo and Band Overhaul 129 Transmission Assembly and Adjustment . . . . . . 139
Governor and Park Gear Overhaul 115 Transmission Case Cleaning and Inspection . . . 113
Oil Pump and Reaction Shaft Support Overhaul . 116 Transmission Disassembly 107
Overhaul Service Information 112
Valve Body Service and Adjustment 131
Overrunning Clutch—Low-Reverse Drum—Rear
Support Overhaul 113
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(3) Mount transmission in repair stand C-3750-B
(Fig. 1).
Fig. 2 Adapter Housing Removal/Installation
Fig. 1 Transmission Mounted On Repair Stand

(4) Remove nuts attaching adapter housing to
transmission case.
(5) Remove adapter housing and gasket (Fig. 2). Fig. 3 Park/Neutral Position Switch Removal/
Installation
(6) Remove rear bearing and snap ring, if
(9) Remove hex head valve body attaching bolts
equipped. (Fig. 5).
(7) Remove park/neutral position switch and seal (10) Disconnect solenoid wire from case connector
(Fig. 3). (Fig. 6).
(8) Remove oil pan bolts and remove pan and gas (11) Lift valve body upward, guide park rod out of
ket (Fig. 4). case opening and remove valve body (Fig. 5).
21 - 108 32RH TRANSMISSION OVERHAUL J
VALVE
Fig. 4 Oil Pan Removal/installation
Fig. 7 Valve Body Removal/Installation
Fig. 5 Valve Body Attaching Bolt Locations (Typical)
Fig. 8 Removing/Installing Accumulator Piston And

Spring
Fig. 6 Solenoid Wire Connection

(12) Remove accumulator spring and piston (Fig. Fig. 9 Removing/Installing Front Band Reaction Pin
8). Access Plug
(13) Remove front band reaction pin access plug (15) Remove oil pump bolts.
(Fig. 9). Plug is accessible through converter hous (16) Thread bolts of Slide Hammer Tools C - 3 7 5 2
ing. Use 1/4 inch drive extension to remove plug as into threaded holes in pump body flange (Fig. 10).
shown. (17) Bump slide hammer weights outward to re
(14) Loosen front band adjusting screw locknut 4-5 move pump and reaction shaft support assembly from
turns. Then tighten band adjusting screw until band case (Fig. 10).
is tight around front clutch retainer. This prevents (18) Loosen front band adjusting screw until band
front/rear clutches from coming out with pump and is completely loose.
possibly damaging clutch or pump components.
J 32RH TRANSMISSION OVERHAUL 2 1 - 10S
Fig. 13 Removing/Installing Front Band Lever

Fig. 10 Removing Oil Pump/Reaction Shaft Support
(22) Slide front band rearward and onto driving
(19) Squeeze front band together and remove band
shell. Band will not be removed until after front/rear
strut (Fig. 11).
clutch removal.
(23) Remove front and rear clutch units as assem
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 14).
Fig. 11 Removing/Installing Front Band Strut

(20) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 12).
J9121-124
Fig. 14 Removing Front/Rear Clutch Assemblies

(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for overhaul.
(25) Remove output shaft thrust washer from out
put shaft (or from rear clutch hub).
(26) Remove output shaft thrust plate from output
shaft hub (Fig. 16).
Fig. 12 Removing Front Band Reaction Pin (27) Slide front band off driving shell (Fig. 17) and
(21) Remove front band lever (Fig. 13) remove band from case.
(28) Remove governor body snap ring (Fig. 18).
21 - 110 32RH TRANSMISSION OVERHAUL
FRONT ^ DRIVING
CLUTCH „ SHELL
< 3 \ l
J9121-127
Fig. 17 Front Band Removal/Installation

REAR
CLUTCH J9121-125
GOVERNOR PARK
BODY GEAR
Fig. 15 Separating Front/Rear Clutch Assemblies SNAP
RING
OUTPUT
SHAFT
THRUST Fig. 18 Removing/Installing Governor Body Snap
PLATE J912U26 Ring
E-CLIP (2 R E Q ' D ) GOVERNOR

Fig. 16 Removing/Installing Output Shaft Thrust VALVE
Plate SHAFT
(29) Remove E-clip from one end of governor valve

shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(30) Loosen bolts attaching governor body to park
gear.
(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft.
(33) Remove planetary geartrain as assembly (Fig.
21). Support geartrain with both hands during re
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched. Fig. 19 Removing Governor Valve And Shaft
(34) Loosen rear band adjusting screw 4-5 turns.
J 32RH TRANSMISSION OVERHAUL 21 - 111
GOVERNOR/PARK GEAR ASSEMBLY REAR

SUPPORT
HUB
LOW-REVERSE
DRUM SNAP RING J9121-132
Fig. 20 Removing/Installing Governor And Park Fig. 22 Removing Low-Reverse Drum Snap Ring
Gear PARALLEL
JAW
S N A P RING
PLIERS
REAR
PLANETARY B A N D PIVOT
GEARTRAIN J9121-131 AND
REACTION
PINS J9121-133
Fig. 21 Planetary Geartrain Removal
(35) Remove snap ring that secures low-reverse Fig. 23 Removing Rear Band Reaction Pins
drum to rear support hub, however do not remove
drum at this time (Fig. 22).
(36) Remove rear band upper and lower reaction
pins with parallel jaw snap ring pliers (Fig. 23).
Spread plier jaws in pin bore to grip pin. Then twist
and pull pins to remove them as shown.
(37) Remove rear band lever and strut.
(38) Mark position of rear support for assembly
reference (Fig. 24). Use scriber or center punch to
mark case and support.
(39) Remove rear support bolts and remove support
from low-reverse drum and case (Fig. 25). Keep rear
support bolts together for assembly reference.
ASSEMBLY
(40) Remove bolts attaching overrunning clutch • REFERENCE
cam to case (Fig. 26). h MARKS J9121-41
(41) Remove low-reverse drum and overrunning
Fig. 24 Marking Rear Support For Assembly
clutch as assembly. Slide drum and clutch through
Reference
Fig. 25 Removing Rear Support
Fig. 26 Overrunning Clutch Cam Bolt Locations

rear band and out of case. Set drum and clutch as
sembly aside for cleaning and inspection.
(42) Remove rear band from case. Fig. 28 Compressing Rear Servo Spring
(43) Compress front servo rod guide about 3 mm
OVERHAUL SERVICE INFORMATION
(1/8 in.) with Valve Spring Compressor Tool
C-3422-B (Fig. 27). A C-clamp and tool C-4470 can Inspect the transmission bushings during overhaul.
also be used to compress rod guide. Bushing condition is important as worn, scored bush
(44) Remove front servo rod guide snap ring (Fig. ings contribute to low pressures, clutch slip and ac
27). Exercise caution when removing snap ring. celerated wear of other components. However, do not
Servo bore can be scratched or nicked if care is replace bushings as a matter of course. Replace bush
not exercised. ings only when they are actually worn, or scored.
(45) Remove compressor tools and remove front Use recommended tools to replace bushings. The
servo rod guide, spring and servo piston. tools are sized and designed to remove, install and
(46) Compress rear servo spring retainer about 1.5 seat bushings correctly. The bushing replacement
mm (1/16 in.) with C-clamp and Tool C-4470 or SP- tools are included in Bushing Tool Set C-3887-B. The
5560 (Fig. 28). Valve Spring Compressor C-3422-B tool set is manufactured by Miller Tool Co. and is
can also be used to compress spring retainer. available through the dealer tool program.
(47) Remove rear servo spring retainer snap ring. Pre-sized service bushings are available for re
Then remove compressor tools and remove rear servo placement purposes. Only the sun gear bushings are
spring and piston.
J 32RH TRANSMISSION OVERHAUL 21-113
not serviced. Low cost of the sun gear assembly cam. Then lift the cam out of the drum with the bolts
makes it easier to simply replace the gear and bush (Fig. 29). Rotate the cam back and forth to ease re
ings as an assembly. moval if necessary. Remove the clutch roller and
Heli-Coil inserts are recommended for repairing spring assembly from the race afterward.
damaged, stripped or worn threads in aluminum
parts. These inserts are available from most automo
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces
sary. When used on valves, use care to avoid round
ing off sharp edges. Sharp edges are vital as they
prevent foreign matter from getting between the
valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176, or Dexron II™ transmission fluid
during overhaul and assembly.
Use petroleum jelly, Door Eze, Ru-Glyde, or similar
Fig. 29 Removing Overrunning Clutch From Low-
products to prelubricate seals, O-rings, and thrust
Reverse Drum
washers. Petroleum jelly can also be used to hold
parts in place during reassembly. CLEANING AND INSPECTION
Clean the overrunning clutch assembly, clutch
TRANSMISSION CASE CLEANING AND cam, low-reverse drum and rear support in solvent.
INSPECTION Dry them with compressed air after cleaning.
Clean the case in a solvent tank. Flush the case Inspect condition of each clutch part after cleaning.
bores and fluid passages thoroughly with solvent. Replace the overrunning clutch roller and spring as
Dry the case and all fluid passages with compressed sembly if any rollers or springs are worn or dam
air. Be sure all solvent is removed from the case and aged, or if the roller cage is distorted, or damaged.
that all fluid passages are clear. Replace the cam if worn, cracked or damaged.
Do not use shop towels or rags to dry the case
Replace the low-reverse drum if the clutch race,
(or any other transmission component) unless
roller surface or inside diameter is scored, worn or
they are made from lint-free materials. Lint will
damaged. Do not remove the clutch race from the
readily adhere to case surfaces and transmission
components and will circulate throughout the low-reverse drum under any circumstances. Re
transmission after assembly. A sufficient quan place the drum and race as an assembly if either
tity of lint can block fluid passages and interfere component is damaged.
with valve body operation. Examine the rear support carefully for wear,
Inspect the case for cracks, porous spots, worn cracks, scoring or other damage. Be sure the support
bores, or damaged threads. Damaged threads can be hub is a snug fit in the case and drum. Replace the
repaired with Helicoil thread inserts. However, the support if worn or damaged.
case will have to be replaced if it exhibits any type of
damage or wear. ASSEMBLING OVERRUNNING CLUTCH/LOW-
Lubricate the front band adjusting screw threads REVERSE DRUM
with petroleum jelly and thread the screw part-way (1) Assemble clutch rollers and springs in retainer
into the case. Be sure the screw turns freely. if necessary (Fig. 30).
Remount the case in Repair Stand C-3750-B after (2) Install overrunning clutch roller, spring and re
cleaning and inspection. tainer assembly in clutch cam (Fig. 31).
(3) Temporarily assemble and check overrunning
OVERRUNNING CLUTCH—LOW-REVERSE clutch operation as follows:
DRUM—REAR SUPPORT OVERHAUL (a) Assemble cam and clutch.
(b) Install clutch assembly on low-reverse drum
DISASSEMBLING OVERRUNNING CLUTCH/
LOW-REVERSE DRUM with twisting motion (Fig. 32).
If the clutch assembly came out with the low-re (c) Install drum-clutch assembly in case and in
verse drum, thread two clutch cam bolts into the stall clutch cam bolts.
RETAINER LOW-REVERSE CLUTCH

DRUM RACE ( O N
H U B O F DRUM)
J9121-139
OVERRUNNING
Fig. 30 Overrunning Clutch Rollers, Springs, CLUTCH
Retainer J9121-135
CLUTCH Fig. 32 Temporary Assembly Of Clutch And Drum

ROLLER
ASSEMBLY To Check Operation
LOW-REVERSE DRUM OVERRUNNING
CLUTCH
CAM
ROLLER
AND
SPRING ASSEMBLY
CLUTCH
RACE
CLUTCH CAM
J9121-138
HUB OF
Fig. 31 Assembling Overrunning Clutch And Cam LOW-REVERSE
DRUM
(d) Install rear support and support attaching
bolts.
(e) Check low-reverse drum rotation. Drum J9121-140
should rotate freely in clockwise direction and
lock when turned in counterclockwise direc Fig. 33 Assembled Overrunning Clutch Components
tion (as viewed from front of case).
ADAPTER HOUSING AND PARK LOCK
(4) Note component position for assembly refer
COMPONENT OVERHAUL
ence. Bolt holes in clutch cam are countersunk on
Clean the housing and park lock components in
one side, Be sure this side of cam will face rearward
solvent and dry them with compressed air.
when installed (Fig. 33).
Inspect the output shaft bearing in the housing
(5) Remove rear support, overrunning clutch and
(Fig. 34). Replace the bearing if worn, damaged, or
low-reverse drum. Set components aside for final as
noisy.
sembly. If overrunning clutch will be installed
Examine the park lock components in the housing.
before final assembly, install cam only as de
If replacement is necessary, remove the shaft with
scribed in Transmission Assembly And Adjust
parallel jaw snap ring pliers (Fig. 35) and remove the
ment section. Clutch cam must be properly
sprag and spring. Then remove the spring clip and
indexed in case to fit and operate properly.
reaction plug (Fig, 36).
Fig. 34 Adapter housing Bearing

Compress the reaction plug spring clip only
enough to remove or install it. The clip i s easily
distorted i f overcompressed. Replace the clip i f
it becomes bent or distorted. Do not straighten
and reuse the clip i f this occurs.
Be sure a replacement sprag is installed so the
sprag locking lug will face the park gear (Fig. 37).
Also be sure the spring is correctly positioned as
shown (Fig. 37). The sprag may not retract if the
spring is improperly installed.
J9121-47
Fig. 37 Correct Position Of Sprag And Spring

and remove shaft and valve from governor body.
(4) Slide governor and park gear off output shaft.
Fig. 35 Park Sprag, Shaft And Spring Removal (5) Remove governor retaining bolts and separate
GOVERNOR AND PARK GEAR OVERHAUL governor from park gear.
(6) Remove governor filter from park gear. Keep
GOVERNOR/PARK GEAR DISASSEMBLY filter with governor body.
(1) Loosen bolts attaching governor to park gear. (7) Remove governor weight snap ring and remove
(2) Remove governor snap ring and locating snap weight assembly from governor body. Remove inner
ring from output shaft (Fig. 38). snap ring and separate governor weights.
(3) Remove E-clip securing governor valve shaft
GOVERNOR/PARK GEAR CLEANING AND PARK REAR FRONT

INSPECTION GEAR SEAL SEAL
RING RING
Clean the governor and park gear components in
solvent and dry with compressed air.
Examine the governor components carefully (Fig.
38). Discard any snap rings or E-clips if distorted, or
worn. Be sure the governor weights operate freely in
the bores and do not bind. Also verify that the gov
ernor valve slides freely on the shaft and in the bore.
Minor scratches, or burrs on governor components
can be cleaned up with oil-soaked crocus cloth. How
ever, do not attempt to salvage components that are
severely worn or scored.
The governor valve used in 1992-93 transmis
sions is now made of aluminum. In addition, the
output shaft has been spotfaced to accept the
new aluminum valve (Fig. 38). The aluminum
valve must not be used in previous 32RH trans
missions. The valve can only be used with an
output shaft that has been spotfaced for valve
end clearance. In addition, the governor body
and output shaft must be properly indexed dur
ing reassembly. Be sure to index these compo
nents as described in the Transmission
Assembly and Adjustment procedures.
Check condition of the park gear seal rings, ring
grooves and gear teeth (Fig. 39). Replace the gear as
an assembly if the teeth or ring grooves are worn, or J9121-48
damaged.
Replace the park gear front and rear seal rings if Fig. 39 Park Gear And Seal Rings
cracked, or worn. The production style front ring is a
ASSEMBLING GOVERNOR AND PARK GEAR
plain type and the rear ring is a hook style. If re
(1) Coat governor body bores and valves with
placement rings are both hook-style, be sure the ring
transmission fluid.
ends are properly hooked together.
(2) Assemble governor weights and springs. Then
SPRING install weight assembly in governor body but do not
install valve and shaft at this time. These parts are
OUTER WEIGHT
not installed until after governor and park gear are
in place on output shaft.
VALVE, S H A F T
(3) Install new seal rings on park gear if neces
SNAP* sary.
RINGS VALVE (4) Insert filter screen in park gear and position
governor body on park gear.
INNER WEIGHT
SNAP
(5) Tighten governor body attaching bolts finger
RING tight only. Bolts will not be final tightened until af
ter governor and park gear are mounted on output
shaft.
FILTER SCREEN
OIL PUMP AND REACTION SHAFT SUPPORT

OVERHAUL
PUMP AND SUPPORT DISASSEMBLY

(1) Remove seal from around pump housing (Fig.
40).
GOVERNOR (2) Mark pump housing and support assembly for
VALVE alignment reference.
SPOTFACE J9221-51 (3) Loosen bolts that attach pump body to support
(Fig. 41).
Fig. 38 Governor Components (4) Remove pump-to-support bolts and separate
support from pump housing (Fig. 42).
32RH TRANSMISSION OVERHAUL 2 1 - 117
, REACTION PUMP
PUMP
SHAFT HOUSING
HOUSING
SUPPORT
SEAL
RING
J9321-211 J9321-213
Fig. 40 Removing Pump Housing Seal F i g . 42 Separating Pump Housing From Reaction
Shaft Support-32RH
SUPPORT
REACTION
TO
SHAFT
PUMP OUTER
SUPPORT INNER
BOLTS (6) GEAR GEAR
i ^ m ^ ^ m o r J9321-212
J9321-214
F i g . 41 Loosening Pump Support Bolts
F i g . 43 Pump Gear Removal—32RH
(5) Remove inner and outer gears from reaction
shaft support (Fig. 4 3 ) . (7) Remove front clutch thrust washer from sup
(6) If pump seal was not removed during transmis port hub (Fig. 44).
sion disassembly, remove seal with punch and ham
mer.
REACTION S H A F T GASKET
WASHER
J9321-207
F i g . 44 Oil Pump And Reaction Shaft Support Components—32RH

OIL PUMP AND REACTION SHAFT SUPPORT FEELER

CLEANING AND INSPECTION GAUGE
Clean pump and reaction shaft support components INNER
GEAR
with solvent and dry them with compressed air.
Inspect the pump housing and support components.
Replace the housing or support if the seal ring
grooves or machined surfaces are worn, scored, pit
ted, or damaged.
Replace the pump gears if pitted, worn chipped, or
damaged. Inspect the thrust washer for wear or dam J9321-216
age. Replace the washer if necessary. Note that the
inner gear used in 1993 32RH oil pumps has a Fig. 46 Measuring Pump Housing-To-Inner Gear
new design drive lug. The new design incorpo Clearances—32RH
rates drive flats instead of the square lug used
previously. The 1993 torque converter hub has
INNER,
also been redesigned to accept the new drive. If GEAR
pump gear replacement is necessary, be very
sure to order and install the new style gears.
Inspect the pump and reaction shaft support bush
ings. Minor bushing wear is acceptable. Replace the OUTER
GEAR
bushings only if scored, or severely worn.
Install the gears in the pump housing and measure
end clearance with a feeler gauge and straightedge
(Fig. 45). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.). Fig. 47 Measuring Pump Gear Tooth
S T R A I G H T EDGE
Clearance—32RH
SPECIAL BUSHING
TOOL REMOVAL
FEELER C-4171
GAUGE
SPECIAL TOOL
SP-3551
PUMP HOUSING
BUSHING
Ij'l! J9321-215
Fig. 45 Measuring Pump Gear End Clearance—32RH SPECIAL

TOOL
Measure clearance between the outer gear and the C-4171 SPECIAL
TOOL
pump body (Fig. 46). Clearance should be 0.08 - 0.19 SP-5117
mm (0.0035 - 0.0075 in.).
Measure gear tooth clearance with a feeler gauge.
Align one tooth of the outer gear in inner gear and
measure clearance (Fig. 47). Clearance should be
0.08 - 0.19 mm (0.0035 - 0.0075 in.).
BUSHING
OIL PUMP BUSHING REPLACEMENT J9221-242

(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 48). Fig. 48 Removing Oil Pump Bushing—32RH
(2) Install new pump bushing with Tool Handle REACTION SHAFT SUPPORT BUSHING
C-4171 and Bushing Installer SP-5117 (Fig. 48). REPLACEMENT
Bushing should be flush with pump housing bore. (1) Assemble Bushing Remover Tools SP-1191,
(3) Stake new pump bushing in two places with 3633 and 5324 (Fig. 50). Do not clamp any part of
blunt punch (Fig. 49). Remove burrs from stake reaction shaft or support in vise.
points with knife blade afterward.
J — 32RH TRANSMISSION OVERHAUL 21 - 119
(4) Install outer gear in pump housing (Fig. 51).

Gear can be installed either way (it is not a one-way
fit).
OUTER
GEAR
Fig. 49 Staking Oil Pump Bushing—All

(2) Hold Cup Tool SP-3633 firmly against reaction
shaft and thread remover SP-5324 into bushing as J9321-219
far as possible by hand. Then thread remover tool 3-4
additional turns into bushing with a wrench. Fig. 51 Supporting Pump And Installing Outer
(3) Turn remover tool hex nut down against re Gear-32RH
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal. (5) Install pump inner gear (Fig. 52). Gear can be
(4) Lightly grip old bushing in vise or with pliers installed either way (it is not a one-way fit).
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
INNER
SP-5325 (Fig. 50). GEAR
(6) Slide new bushing onto Installer Tool SP-5325. OUTER-
GEAR
(7) Position reaction shaft support upright on a
clean smooth surface.
(8) Align bushing in bore. Then tap bushing into
place until Bushing Installer SP-5325 bottoms.
(9) Clean reaction shaft support thoroughly after
installing bushing.
J9321-220
Fig. 52 Pump Inner Gear Installation—32RH

(6) Install new thrust washer on hub of reaction
shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
(7) If reaction shaft seal rings are being replaced,
install new seal rings on support hub (Fig. 53). Lu
bricate seal rings with transmission fluid or petro
leum jelly after installation. Squeeze each ring until
ring ends are securely hooked together.
Fig. 50 Replacing Reaction Shaft Support CAUTION: T h e reaction shaft support seal rings
Bushing—32RH will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal
ASSEMBLING OIL PUMP AND REACTION lation. Also be very sure the ring ends are securely
SHAFT SUPPORT hooked together after installation. Otherwise, the
(1) Lubricate gear bore in pump housing with rings will either prevent pump installation, or break
transmission fluid. during installation.
(2) Lubricate pump gears with transmission fluid. (8) Install reaction shaft support on pump housing
(3) Support pump housing on wood blocks (Fig. 51). (Fig. 54).
SEAL REACTION
SHAFT
RINGS PUMP SUPPORT
HOUSING
SUPPORT
HUB J9321-218 If J9321-221
Fig. 53 Hub Seal Ring Position-32RH Fig. 54 Assembling Reaction Shaft Support And
(9) Align reaction support on pump housing. Use Pump Housing—32RH
alignment marks made at disassembly. Or, rotate
support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit). SPECIAL
TOOL
(10) Install all bolts that attach support to pump
C-4193
housing. Then tighten bolts finger tight.
PUMP
(11) Tighten support-to-pump bolts to required
BODY
torque as follows:
(a) Reverse pump assembly and install it in PUMP
transmission case. Position pump so bolts are fac SEAL
ing out and are accessible.

(b) Secure pump assembly in case with 2 or 3 J9321-183
bolts, or with pilot studs. Fig. 55 Pump Oil Seal Installation—32RH
(c) Tighten support-to-pump bolts to 20 N»m (15
ft. lbs.). (14) Lubricate lip of pump oil seal and O-ring seal
(d) Remove pump assembly from transmission with transmission fluid.
case.
(12) Install new oil seal in pump with Special Tool FRONT CLUTCH OVERHAUL
C-4193 and Tool Handle C-4171 (Fig. 55). Be sure
seal lip faces inward. FRONT CLUTCH DISASSEMBLY
(13) Install new seal ring around pump housing. (1) Remove waved snap ring and remove pressure
Be sure seal is properly seated in groove. plate, clutch plates and clutch discs (Fig. 56).
RETAINER H U B
SEAL
CLUTCH S N A P RING
PISTON (WAVED)
PISTON
SPRING SPRING
RETAINER
S N A P RING
PRESSURE
PLATE
F R O N T CLUTCH R E T A I N E R
CLUTCH PLATES J9321-222
Fig. 56 Front Clutch Components—32RH

if 32RH TRANSMISSION OVERHAUL 21 - 121
(2) Compress clutch piston spring with Compressor with crocus cloth. However, replace the piston and/or
Tool C-3575-A (Fig. 57). Be sure legs of tool are retainer if the seal surfaces are seriously scored.
seated squarely on spring retainer before compress
RETAINER
ing spring. CHECK BALL
(3) Remove retainer snap ring and remove com
pressor tool.
J9121-368
Fig. 58 Front Clutch Piston Retainer Check Ball

Location—32RH
RETAINER \ ^ SNAP RING /J912M47

Fig. 57 Compressing Front Clutch Piston
Spring-32RH
(4) Remove spring retainer and clutch spring. Note
position of retainer on spring for assembly reference.
(5) Remove clutch piston from clutch retainer. Re
move piston by rotating it up and out of retainer.
(6) Remove seals from clutch piston and clutch re
tainer hub. Discard both seals as they are not reus
able.
FRONT CLUTCH INSPECTION
Clean the front clutch components in solvent and Fig. 59 Retainer Bushing Locations—32RH
dry them with compressed air only. Do not use rags
or shop towels to dry any of the clutch parts. Lint FRONT CLUTCH ASSEMBLY
from such materials will adhere to the component (1) Soak clutch discs in transmission fluid while
surfaces and could restrict or block fluid passages af assembling other clutch parts.
ter assembly. (2) Check piston spring fit. Trial fit each end of
Replace the clutch discs if warped, worn, scored, spring in piston (Fig. 60). One end of spring has
burned or charred, or if the facing is flaking off. Re slightly larger inside diameter. This end will be
place the steel plates if heavily scored, warped, or slip fit over hub of piston and ensure full spring
broken. Be sure the driving lugs on the plates are in seating. Mark spring with chalk or paint after
good condition. The lugs must not be bent, cracked or determining which end is best fit in spring seat.
damaged in any way. (3) Install new seals on piston and in hub of re
Replace the clutch spring and spring retainer if ei tainer. Be sure lip of each seal faces interior of clutch
ther is distorted, warped or broken. retainer.
Check the lug grooves in the clutch retainer. The (4) Lubricate lips of piston and retainer seals with
steel plates should slide freely in the slots. Replace liberal quantity of Door Eze, or petroleum jelly. Then
the retainer if the grooves are worn or damaged. lubricate retainer hub, bore and piston with trans
Check action of the check ball in the retainer (Fig. mission fluid.
58). The ball must move freely and not stick. (5) Install clutch piston in retainer (Fig. 61). Use
Inspect the clutch retainer bushings carefully twisting motion to seat piston in bottom of retainer.
(Fig. 59). The retainer bushings are not service Do not attempt to push the piston straight in.
able. It will be necessary to replace the retainer This could fold the seals over causing leakage
if either bushing is scored, or worn. and clutch slip.
Inspect the piston and retainer seal surfaces for (6) Position spring in clutch piston.
nicks or scratches. Minor scratches can be removed
(10) Install pressure plate and waved snap ring
TRIAL FIT
SPRING FOR
(Fig. 56).
CORRECT FIT (11) Check clutch plate clearance (Fig. 63). Clear
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.).
I f clearance is incorrect, clutch discs, plates pressure
plates and snap ring may have to be changed.
J9321-225
Fig. 60 Checking Spring Fit In Clutch

Piston-32RH
Fig. 61 Front Clutch Piston Installation—32RH FEELER GAUGE RH288
(7) Position spring retainer on top of piston spring Fig. 63 Measuring Front Clutch Pack Clearance
(Fig. 62). Make sure retainer is properly in
stalled. Small raised tabs should be facing up REAR CLUTCH OVERHAUL
ward. Semicircular lugs on underside of retainer
REAR CLUTCH DISASSEMBLY
are for positioning retainer in spring.
(1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove selective clutch pack snap ring (Fig.
64).
(3) Remove top pressure plate, clutch discs, steel
plates, bottom pressure plate and wave spring (Fig.
64).
(4) Remove clutch piston with rotating motion.
(5) Remove and discard piston seals.
(6) Remove input shaft snap ring (Fig. 65).
(7) Press input shaft out of retainer with shop
press and suitable size press tool (Fig. 66).
Fig. 62 Correct Spring Retainer Installed (8) Remove input shaft front/rear seal rings.
Position—32RH
REAR CLUTCH INSPECTION
(8) Compress piston spring and retainer with Com Clean the clutch components with solvent and dry
pressor Tool C-3575-A (Fig. 63). Then install new them with compressed air. Do not use rags or shop
snap ring to secure spring retainer and spring. towels to dry any of the clutch parts. Lint from such
(9) Install clutch plates and discs (Fig. 56). Install materials will adhere to component surfaces and
steel plate then disc until all plates and discs are in could restrict or block fluid passages after assembly.
stalled. Replace the clutch discs i f warped, worn, scored,
burned/charred, the lugs are damaged, or i f the fac-
-REAR
INPUT REAR INPUT CLUTCH
OUTPUT SHAFT CLUTCH SHAFT
SHAFT THRUST
SNAP RETAINER SHAFT WASHER
THRUST RING
WASHER / FRONT (FIBER)
(METAL) SHAFT SEAL
CLUTCH REAR RING C L U T C H
PISTON SEAL n m O N )
[ 1 1
REAR SEALS RING PACK
CLUTCH (METAL) SNAP
PISTON RING
(SELECTIVE)
PISTON
SPRING
TOP
PRESSURE
PLATE
CLUTCH
BOTTOM DISCS (4)
PRESSURE
PLATE
J9121-539
Fig. 64 Rear Clutch Components

REAR CLUTCH INPUT
RETAINER SHAFT
SNAP 1 1
RING y
^P^^^^^^ ^* ^^ PRESS
RAM
REAR
CLUTCH
RETAINER
SNAP
RING J912M50
PLIERS J9121-149
Fig. 66 Pressing Input Shaft Out Of Rear Clutch

Fig. 65 Removing/Installing Input Shaft Snap Ring
Retainer
ing is flaking off. Replace the top and bottom pres
damaged. Also check action of the check balls in the
sure plates if scored, warped, or cracked. Be sure the
retainer and piston. Each check ball must move
driving lugs on the pressure and clutch plates are
freely and not stick.
also in good condition. The lugs must not be bent,
Replace the retainer bushing if worn, scored, or
cracked or damaged in any way.
doubt exists about bushing condition.
Replace the piston spring and wave spring if either
Inspect the piston and retainer seal surfaces for
part is distorted, warped or broken.
nicks or scratches. Minor scratches can be removed
Check the lug grooves in the clutch retainer. The
with crocus cloth. However, replace the piston and/or
clutch and pressure plates should slide freely in the
retainer if the seal surfaces are seriously scored.
slots. Replace the retainer if the grooves are worn or
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The rear
ring is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.
ASSEMBLING REAR CLUTCH

(1) Soak clutch discs in transmission fluid.
(2) Install new seal rings on clutch retainer hub
and input shaft if necessary (Fig. 67).
(a) Be sure clutch hub seal ring is fully seated in
groove and is not twisted.
(b) Note that input shaft front seal ring is teflon
and rear seal ring is metal (Fig. 68). Be sure cham
fered ends of teflon ring are properly joined and
J912M51
that ends of rear ring are securely hooked together.
Lubricate both rings with transmission fluid after Fig. 68 32RH Input Shaft Seal Ring Identification
installation.
J9121-538
Fig. 67 32RH Rear Clutch Retainer And Input Shaft

Seal Ring Installation Fig. 69 Pressing Input Shaft Into Rear Clutch
Retainer
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input attempt to push the piston straight in. This
shaft into retainer (Fig. 69). could fold the seals over causing leakage and
(4) Install input shaft snap ring (Fig. 65). clutch slip.
(5) Install new seals on clutch piston. Be sure lip (8) Install piston spring in retainer and on top of
of each seal faces interior of clutch retainer. piston (Fig. 7 0 ) . Concave side of spring faces down
(6) Lubricate lip of piston seals with liberal quan ward (toward piston).
tity of Door Eze, or petroleum jelly. Then lubricate (9) Install wave spring in retainer (Fig. 7 0 ) . Be
retainer hub and bore with transmission fluid. sure spring is completely seated in retainer groove.
(7) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. Do not
J (15) Coat rear clutch fiber thrust washer with pe
troleum jelly and install washer over input shaft and
into clutch retainer (Fig. 72). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation during fi
PISTON nal assembly.
SPRING
WAVE
SPRING
PISTON J9121-153
Fig. 70 Piston And Wave Spring Position

(10) Install bottom pressure plate (Fig. 64). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
(11) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate fol
lowed by a clutch disc until entire clutch pack is in Fig. 72 Installing Rear Clutch Thrust Washer
stalled. Total of 4 discs and 3 plates are required PLANETARY I EAR TRAIN-OUTPUT SHAFT
(Fig. 64). OVERHAUL
(12) Install top pressure plate (Fig. 64).
(13) Install selective snap ring (Fig. 64). Be sure PLANETARY GEARTRAIN DISASSEMBLY (FIG.
snap ring is fully seated in retainer groove. 73)
(14) Measure clutch pack clearance (Fig. 71). (1) Remove snap ring, tabbed thrust washer and
Clearance should be 0.64 - 1.14 mm (0.025 - 0.045 thrust plate from front of output shaft.
in.). If clearance is incorrect, steel plates, discs, snap (2) Remove front annulus gear and support assem-
ring and pressure plates may have to be changed. bly.
(3) Remove front planetary front thrust washer.
(4) Remove front planetary gear.
(5) Remove front planetary rear thrust washer.
(6) Remove sun gear and driving shell.
(7) Remove snap ring that retains sun gear in
driving shell and remove sun gear and thrust plates.
Note thrust plate position for assembly reference.
(8) Remove tabbed thrust washer from rear plane
tary gear.
(9) Remove rear planetary gear from rear annulus
gear and remove annulus gear from output shaft.
(10) Remove snap rings that secure annulus gears
to supports and separate each gear from the support.
PLANETARY GEARTRAIN INSPECTION

Clean the planetary components in solvent and dry
them with compressed air.
Check sun gear and driving shell condition. Re
place the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable. Re
place the driving shell if worn, cracked or damaged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annu
Fig. 71 Typical Method Of Checking Rear Clutch lus gears and supports if either component is worn or
Pack Clearance damaged.
21 • 126 32RH TRANSMISSION OVERHAUL J
SELECT FRONT SUPPORT A N N U L U S GEAR FRONT SUN SUN DRIVING SHELL F R O N T DRIVING
FIT ANNULUS S N A P RING SUPPORT PLANETARY GEAR GEAR T H R U S T PLATE SHELL
PLANETARY SNAP THRUST SPACER
SNAP RING WASHERS
RING
FRONT
PLANETARY
GEAR
FRONT REAR SUPPORT S N A P RING
ANNULUS PLANETARY LOW-REVERSE
THRUST GEAR, DRUM
WASHER
DRIVING
SHELL
REAR
THRUST REAR
PLATE S U N GEAR REAR PLANETARY ANNULUS ANNULUS
LOCK RING THRUST WASHERS GEAR GEAR S U P P O R T
OUTPUT
SHAFT
THRUST OUTPUT
J9221-17
PLATE SHAFT
Fig. 73 Output Shaft And Planetary Components

Inspect the geartrain spacers, thrust plates, snap (4) Install rear annulus over and onto rear plane
rings, and thrust washers. Replace any of these parts tary gear (Fig. 74).
that are worn, distorted or damaged. Do not attempt
to reuse these parts.
Inspect the output shaft carefully. Pay particular
attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also re
place the shaft if the splines are damaged, or exhib
its cracks at any location (especially at the governor
valve shaft bore).
ASSEMBLING PLANETARY GEARTRAIN

(1) Lubricate output shaft and planetary compo
nents with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in posi
tion. Fig. 74 Assembling Rear Annulus And Planetary
(2) Assemble rear annulus gear and support if dis Gear
assembled. Be sure support snap ring is seated and
(5) Install assembled rear planetary and annulus
that shoulder-side of support faces rearward (Fig. gear on output shaft (Fig. 75). Verify that assembly
74). is fully seated on shaft.
(3) Install rear thrust washer on rear planetary (6) Install front thrust washer on rear planetary
gear (Fig. 74). Use enough petroleum jelly to hold gear (Fig. 76). Use enough petroleum jelly to hold
washer in place. Also be sure washer tabs are prop washer on gear.
erly engaged in gear slots. (7) Install spacer on sun gear (Fig. 77).
REAR A N N U L U S shell.
A N D PLANETARY G E A R
ASSEMBLY
THRUST
PLATE
OUTPUT
SHAFT
J912M57 SUN
GEAR
Fig. 75 Installing Assembled Rear Annulus And

Planetary Gear On Output Shaft Fig. 78 Installing Driving Shell Front Thrust Plate
FRONT On Sun Gear
TABBED
THRUST
(9) Hold sun gear in place and install thrust plate
WASHER over sun gear at rear of driving shell (Fig. 79).
SUN
DRIVING GEAR
SHELL
REAR
PLANETARY
GEAR J9121-158
Fig. 76 Installing Rear Planetary Front Thrust

REAR
Washer THRUST
PLATE J912M62
Fig. 79 Installing Driving Shell Rear Thrust Plate

(10) Position wood block on bench and support sun
SUN gear on block (Fig. 80). This makes it easier to align
GEAR and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
(11) Align rear thrust plate on driving shell and
install sun gear lock ring. Be sure ring is fully
seated in sun gear ring groove (Fig. 81).
SUN GEAR
(12) Install assembled driving shell and sun gear
SPACER on output shaft (Fig. 82).
(13) Install rear thrust washer on front planetary
J912M59 gear (Fig. 83). Use enough petroleum jelly to hold
washer on gear and be sure washer tabs are all prop
Fig. 77 Installing Spacer On Sun Gear erly seated.
(8) Install thrust plate on sun gear (Fig. 78). Note (14) Install front planetary gear on output shaft
that driving shell thrust plates are interchangeable. and in driving shell (Fig. 84).
Use either plate on sun gear and at front/rear of
Fig. 80 Supporting Sun Gear On Wood Block Fig. 83 Installing Rear Thrust Washer On Front
Planetary Gear
(16) Assemble front annulus gear and support. Be
sure support snap ring is seated.
(17) Position thrust plate on front annulus gear
support (Fig. 85). Use enough petroleum jelly to hold
thrust plate in place.
(18) Install front annulus assembly on front plane
tary gear (Fig. 84).
Fig. 81 Installing Sun Gear Lock Ring
Fig. 84 Installing Front Planetary And Annulus

Gears
(19) Install front annulus thrust washer (Fig. 86).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
(20) Install front annulus snap ring (Fig. 87). Use
snap ring pliers to avoid distorting ring during in
stallation. Also be sure ring is fully seated.
Fig. 82 Installing Assembled Sun Gear And Driving (21) Install planetary selective snap ring with snap
Shell On Output Shaft ring pliers (Fig. 88). Be sure ring is fully seated.
(22) Turn planetary geartrain assembly over so
(15) Install front thrust washer on front planetary
driving shell is facing workbench. Then support
gear (Fig. 84). Use enough petroleum jelly to hold
geartrain on wood block positioned under forward
washer in place on gear and be sure washer tabs are
seated.
SELECTIVE
Fig. 85 Positioning Thrust Plate On Annulus Fig. 88 Installing Planetary Selective Snap Ring
Support (23) Check planetary geartrain end play with
feeler gauge (Fig. 89). Gauge goes between shoulder
on output shaft and end of rear annulus support.
(24) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ring
(or thrust washers) may have to be replaced. Snap
ring is available in three different thicknesses for ad
justment purposes.
Fig. 86 Installing Front Annulus Thrust Washer
Fig. 89 Checking Planetary Geartrain End Play

FRONT SERVO AND BAND OVERHAUL
FRONT SERVO DISASSEMBLY (FIG. 90)

Fig. 87 Installing Front Annulus Snap Ring (1) Remove small snap ring from servo piston.
end of output shaft. This allow geartrain components (2) Remove piston, rdd, springs and guide.
to move forward for accurate end play check. (3) Remove and discard servo piston rings and
O-ring.
FRONT SERVO AND BAND INSPECTION (4) Open vise and remove wood block, piston plug,
Clean the servo components with solvent and dry cushion spring and servo piston.
Inspect the servo components. Replace the springs
if collapsed, distorted or broken. Replace the guide,
rod and piston if cracked, bent, or worn. Discard the
servo snap ring if distorted or warped.
Replace the front band if distorted, the lining is
burned or flaking off, or excessively worn.
Check the servo piston bore for wear. Replace the
piston and rod as an assembly if either part is worn
or damaged.
Replace any servo component if doubt exists about
its condition. Do not reuse suspect parts.
SERVO
PISTON
Fig. 91 Removing/installing Servo Piston Plug Snap

Ring
REAR SERVO INSPECTION
Clean the servo components with solvent and dry
Check rear band condition. Replace the band if dis
torted, the lining is burned or flaking off, or the lin
ing is excessively worn.
Check the band reaction pins. Replace the O-rings
on both pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace the pins if worn,
severely scored, or cracked.
Inspect the servo components (Fig. 92). Replace the
servo and cushion springs if collapsed, distorted or
broken. Replace the plug or piston if cracked, bent,
L
RING ^ J9121-172
Fig. 90 Front Servo Components

ASSEMBLING FRONT SERVO PISTON
(1) Lubricate servo parts with transmission fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install
new seal rings on piston.
(4) Assemble rod, piston, servo springs and snap
ring (Fig. 90).
REAR SERVO AND BAND OVERHAUL
REAR SERVO PISTON DISASSEMBLY

(1) Remove seal from servo piston. Note which way
seal lip faces for assembly reference.
(2) Compress cushion spring in vise only enough to
allow piston plug snap ring removal (Fig. 91). Use
wood block between vise jaws and end of piston plug
to keep plug aligned and in position.
(3) Remove snap ring from end of piston plug (Fig.
91). Fig. 92 Rear Servo Components
32RH TRANSMISSION OVERHAUL 21-131
or worn. Discard the servo snap ring and spring re MANUAL CONVERTER
tainer if distorted or warped. LEVER CLUTCH
MODULE
If doubt exists about the condition of any servo A N D TUBE
component, replace it. Do not reuse suspect parts.
ASSEMBLING REAR SERVO PISTON

(1) Assemble piston plug, cushion spring and pis
ton (Fig. 92).
(2) Compress cushion spring in vise and install pis
ton plug snap ring (Fig. 92).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 93). MANUAL
VALVE
(4) Lubricate piston seal with petroleum jelly. Lu
bricate other servo parts with transmission fluid.
BE S U R E
S E A L LIP CONVERTER
IS T O W A R D SOLENOID CLUTCH
S E R V O BORE WIRE SOLENOID
PARK
ROD J932M25
REAR
SERVO Fig. 94 Valve Body Assembly
PISTON
LINE THROTTLE
J9121-175 PRESSURE PRESSURE
REGULATOR ADJUSTING
Fig. 93 Installing Rear Servo Piston Seal VALVE SCREW AND
SPRING BRACKET
VALVE BODY SERVICE AND ADJUSTMENT LINE
PRESSURE
VALVE BODY DISASSEMBLY ADJUSTING
SCREW
CAUTION: Do not clamp any part of the valve body
assembly (Fig. 94) in a vise. T h i s practice will dis
tort the valve body and transfer plate resulting in
valve bind. Slide valves and plugs out carefully. Do
not use force at any time. T h e valves and valve mm
body will be damaged if force i s used. Also tag or SWITCH
mark the valve body springs for reference as they VALVE
SPRING J9121-176
are removed. Do not allow them to become inter
mixed. Fig. 95 Adjusting Screw Bracket And Spring
Removal
(1) Remove screws attaching adjusting screw
bracket to valve body and transfer plate. Hold SPECIAL
bracket firmly against spring force while removing TOOL 6583
last screw.
(2) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 95). Do not remove throttle
pressure adjusting screw from bracket and do
not disturb adjusting screw settings during re
moval.
(3) Secure detent ball and spring in housing with
DETENT BALL AND SPRING HOUSING J932M21
retainer tool 6583 (Fig. 96).
(4) Remove manual shaft E-clip and washer (Fig. Fig. 96 Securing Detent Ball And Spring With
97). Retainer Tool
(5) Pull manual shaft and park rod assembly up
ward out of valve body and off throttle lever (Fig. (6) Remove Retainer Tool 6583. Then remove and
97). retain detent ball and spring.
(7) Remove throttle lever (Fig. 97). (10) Turn valve body over so transfer plate is fac
SHUTTLE
ing upward (Fig. 100). With valve body in this posi
VALVE PARK tion, valve body check balls will remain in place and
E N D PLATE ROD not fall out when transfer plate is removed.
(11) Remove screws attaching transfer plate to
valve body (Fig. 100).
MANUAL VALVE
LEVER BODY
VALVE SCREWS
BODY
SCREWS
MANUAL LEVER ^ §
LEVER WASHER <Z
D E T E N T BALL A N D E-CLIP
AND SPRING
J9121-177 VALVE
BODY
Fig. 97 Removing Manual And Throttle Levers SCREWS
(8) Remove park rod E-clip and separate rod from

manual lever (Fig. 98). VALVE
BODY
MANUAL
LEVER
TRANSFER
PLATE J912M81
Fig. 100 Valve Body- To- Transfer Plate Screw

Locations
(12) Remove transfer plate and separator plate
from valve body. Note position of filter and clutch so
lenoid for reference (Fig. 101).
TRANSFER
PLATE
PARK
ROD J9121-81
Fig. 98 Park Rod Removal

(9) Remove screws attaching converter clutch mod
ule to valve body and remove module and connecting
tube (Fig. 99).
MODULE CONVERTER
A N D CONNECTING TUBE CLUTCH
SOLENOID
VALVE
FILTER BODY J9321-124
Fig. 101 Transfer Plate Removal/Installation
J9121-178
Fig. 99 Module And Connecting Tube Removal/

Installation
(13) Position transfer plate on bench so separator SEPARATOR

plate, filter and lockup solenoid are facing up. This
will avoid having rear clutch and rear servo check
balls fall out when plates are separated.
(14) Remove screws attaching separator plate to
transfer plate.
(15) Remove converter clutch solenoid from separa
tor plate (Fig. 102).
CONVERTER /
Fig. 102 Removing Converter Clutch Solenoid
(16) Note position of filter, solenoid and rear J912M82

clutch/rear servo check balls for assembly reference
(Fig. 103). Fig. 103 Transfer And Separator Plates
(17) Remove shuttle valve end plate (Fig. 104).
(18) Remove shuttle valve E-clip and remove sec
ondary spring and spring guides from end of valve
(Fig. 104).
(19) Remove governor valve end plate (Fig. 105).
(20) Remove switch valve and pressure regulator
valve from valve body (Fig. 105).
(21) Remove throttle valve and spring, kickdown
valve and detent and manual valve from valve body
(Fig. 105).
(22) Remove 1-2 and 2-3 shift valve governor plugs
from valve body (Fig. 105).
(23) Remove shuttle valve throttle plug, primary
spring and shuttle valve from valve body (Fig. 105).
(24) Remove 1-2 shift control valve and spring
from valve body (Fig. 106).
(25) Remove 2-3 shift valve and spring from valve
Fig. 104 Shuttle Valve E-Clip And Secondary Spring
body (Fig. 106).
Location
(26) Remove 1-2 shift valve and spring from valve
body (Fig. 106). • pressure adjusting screw bracket
(27) Remove regulator valve end plate (Fig. 106). • throttle valve lever
(28) Remove regulator valve line pressure plug, • manual lever
pressure plug sleeve, throttle pressure plug and • manual lever shaft seal, washer, E-clip and detent
spring (Fig. 106). ball
• fluid filter
VALVE BODY CLEANING AND INSPECTION • converter clutch solenoid
The only serviceable valve body components are: The remaining valve body components are serviced
• park lock rod and E-clip only as part of a complete valve body assembly.
• switch valve and spring
E N D PLATE J9121-50
Fig. 105 Control Valves And Governor Plugs
J912M80
Fig. 106 Shift Valves And Pressure Regulator Plugs

Clean the valve body components in a parts clean (or by testing with a magnet). DO NOT polish or
ing solution only. Do not use gasoline, kerosene, or sand aluminum valves or plugs with any type of
any type of caustic solution. Dry the parts with com material, or under any circumstances. This practice
pressed air. Make sure all passages are clean and might damage the special coating and cause the
free from obstructions. valves and plugs to stick and bind.
D o n o t use rags o r shop towels t o w i p e off
valve body components. Lint from these materi Inspect the valves and plugs for scratches, burrs,
als will adhere to the valve body components. nicks, or scores. Also inspect the coating on the alu
Lint will interfere with valve operation and may minum valves and plugs (Fig. 107). If the coating is
clog filters and fluid passages. damaged or worn through, the valve (or valve body)
Inspect the throttle and manual valve levers and should be replaced.
shafts. Do not attempt to straighten a bent shaft or Aluminum valves and plugs should not be sanded
correct a loose lever. Replace these components if or polished under any circumstances. However, mi
worn, bent, loose or damaged in any way. nor burrs or scratches on steel valves and plugs can
Inspect all of the valve body mating surfaces for be removed with crocus cloth but do not round off the
scratches, nicks, burrs, or distortion. Use a straight valve or plug edges. Squareness of these edges is vi
edge to check surface flatness. Minor scratches may tally important. These edges prevent foreign matter
be removed with crocus cloth using only very light from lodging between the valves, plugs and bore.
pressure. Inspect all the valve and plug bores in the valve
Minor distortion of a valve body mating surface body. Use a penlight to view the bore interiors. Re
may be corrected by smoothing the surface with cro place the valve body if any bores are distorted or
cus cloth. The cloth should be in sheet form and be scored. Inspect all of the valve body springs. The
positioned on a surface plate, sheet of plate glass, or springs must be free of distortion, warpage or broken
equally flat surface. However, if distortion is severe coils.
or any surfaces are heavily scored, the valve body Trial fit each valve and plug in its bore to check
will have to be replaced. freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
CAUTION: The throttle valve, shuttle valve plug, body bores do not change dimensionally with use. If
1-2 shift valve and 1-2 governor plug are made o f the valve body functioned correctly when new, it will
coated aluminum. These components are identified continue to operate properly after cleaning and in
in Figure 107 with the abbreviation (Alum.). Alumi spection. It should not be necessary to replace a
num components can be identified by the dark valve body assembly unless it is damaged in han
color of the special coating applied to the surface dling.
SHIFT VALVE 2-3 SHIFT S H U T T L E VALVE
E N D PLATE VALVE A N D SECONDARY SPRING,
SPRING G U I D E S , E-CLIP
1-2 SHIFT
CONTROL VALVE
A N D SPRING
REGULATOR
VALVE
E N D PLATE S H U T T L E VALVE
COVER
REGULATOR
VALVE
PRESSURE
PLUG
2-3 SHIFT
SLEEVE VALVE GOVERNOR
PLUG
REGULATOR
VALVE T H R O T T L E
P R E S S U R E PLUG
S H U T T L E VALVE
PLUG (ALUM.)
GOVERNOR
VALVE E N D
PLATE
MODULE
AND
CONNECTING M A N U A L LEVER
TUBE D E T E N T BALL
PRESSURE A N D SPRING
LINE THROTTLE SWITCH REGULATOR

PRESSURE ADJUSTING PRESSURE VALVE VALVE
ADJUSTING SCREW ADJUSTING AND AND J9121-369
SCREW BRACKET SCREW SPRING SPRING
Fig. 107 Valve Body Components (Alum. Indicates Aluminum Part)

J 32RH T R A N S M I S S I O N OVERHAUL 21-137
VALVE BODY ASSEMBLY 1/4" CHECK BALLS (6)
CAUTION: Do not force waives or plugs into place

during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory op
eration. Tighten valve body screws to recom
mended torque only.
(1) Lubricate valve body bores, valves and plugs

with ATF Plus, or Dexron II™ transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 102).
(3) Install filter screen in separator plate (Fig.
102).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep 11/32" CHECK BALL (1) J912M83
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid Fig. 109 Correct Position Of Valve Body Check
and insert solenoid in separator plate (Fig. 108). Balls
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 106).
(11) Install 1-2 shift control valve and spring (Fig.
106)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 105).
Fig. 108 Installing Converter Clutch Solenoid Tighten end plate screws to 4 N*m (35 in. lbs.)
torque.
(6) Position valve body so internal passages and (14) Install 1-2 and 2-3 valve governor plugs in
check ball seats are facing upward. Then install valve body (Fig. 105). Then install shuttle valve pri
check balls in valve body (Fig. 109). There are a total mary spring and throttle plug.
of seven check balls; The one large check ball is ap (15) Align and install governor plug end plate on
proximately 11/32 inch in diameter. The remaining valve body and install end plate screws. Tighten
check balls are approximately 1/4 inch in diameter. screws to 4 N*m (35 in. lbs.) torque.
(7) Align and install assembled transfer and sepa
(16) Install manual valve (Fig. 105).
rator plates on valve body. Install and tighten valve
(17) Install throttle valve and spring. Then install
body screws alternately in a diagonal pattern to 4
kickdown valve and detent (Fig. 105).
(18) Install pressure regulator valve and switch
(8) Assemble and install lockup module and com
ponents on valve body (Fig. 110). valve in valve body.
(9) Assemble regulator valve line pressure plug, (19) Install manual lever detent spring in housing.
sleeve, throttle plug and spring (Fig. 106). Insert as Place detent ball on end of spring and push ball and
sembly in valve body and install end plate. Tighten spring into housing. Secure ball and spring with De
#
end plate screws to 4 N m (35 in. lbs.) torque. tent Retainer 6583 (Fig. 96).
MODULE
J9321-123
Fig. 110 Converter C I l Module Components

(20) Insert line pressure adjusting screw in adjust
ing screw bracket (Fig. 95).
(21) Install spring on end of line pressure regula
tor valve.
(22) Install switch valve spring on tang at end of
adjusting screw bracket (Fig. 95).
(23) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N*m (35 in. lbs.) torque.
- (24) Install module and connecting tube. Be sure
long end of tube goes to module (Fig. 99). Tighten
module screws to 4 N*m (35 in. lbs.) torque.
(25) Install throttle lever in valve body. Then in
Fig. 111 Manual And Throttle Lever Alignment ,
stall manual lever over throttle lever and start man
ual lever into valve body. (30) I f line pressure and/or throttle pressure ad
(26) Align manual lever detent with detent ball justment screw settings were not disturbed, continue •
and align lever arm with manual valve. Hold throt with overhaul or reassembly. However, i f adjustment
tle lever upward. Then press down on manual lever screw settings were moved or changed, readjust as
until lever is fully seated. described in Valve Body Control Pressure Adjust
(27) Install manual lever seal, washer and retain ment procedure.
ing E-clip.
VALVE BODY CONTROL PRESSURE
(28) Lubricate shaft of manual lever with light
ADJUSTMENTS
coat of petroleum jelly. This will help protect seal lip
There are two control pressure adjustments on the
when manual shaft seal is installed. valve body which are, line pressure and throttle pres
(29) Verify that throttle lever is aligned with end sure.
of kickdown valve stem and that manual lever arm The two pressures are interdependent because each
is engaged in manual valve (Fig. I l l ) , affects shift quality and timing. Each pressure ad-
justment must be performed properly and in the cor

rect sequence. The correct sequence is line pressure
adjustment first and throttle pressure adjustment
last.
Line Pressure Adjustment

Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 112).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
The 33.4 mm (1-5/16 in.) setting is an approxi
mate setting. Because of manufacturing toler
ances, it may be necessary to vary from this
dimension to obtain desired pressure.
Fig. 113 Throttle Pressure Adjustment
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turn sembly. Keep the transmission case and components
ing the adjusting screw counterclockwise increases clean. Also make sure the tools and workbench area
pressure while turning the screw clockwise decreases used for assembly are equally clean.
pressure. Shop towels used for wiping off your hands and ser
vice tools must be made of lint free materials. Lint
will adhere to transmission parts and could interfere
with valve operation, or even restrict fluid passages.
Lubricate the transmission components with ATF
Plus, or Dexron II™ during reassembly. Use petro
leum jelly, Door Eze, or Ru-Glyde on seals and
O-rings to ease installation.
Petroleum jelly can also be used to hold thrust
washers and plates in position during assembly oper
ations. However, do not use chassis grease, bearing
grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and valve
operation. Use petroleum jelly only.
Do not force parts into place. Most of the transmis
sion components are easily installed by hand when
Fig. 112 Line Pressure Adjustment
properly aligned. If a part seems extremely difficult
Throttle Pressure Adjustment to install, it is either misaligned or incorrectly as
Insert Gauge Tool C-3763 between the throttle le sembled. Also verify that thrust washers, thrust
ver cam and the kickdown valve stem (Fig. 113). plates and seal rings are correctly positioned before
Push the gauge tool inward to compress the kick- assembly. These parts can interfere with proper as
down valve against the spring and bottom the throt sembly if mispositioned or "left out" by accident.
tle valve.
Maintain pressure against kickdown valve spring. TRANSMISSION ASSEMBLY PROCEDURE
Turn throttle lever stop screw until the screw head (1) Install rear servo piston, spring and spring re
touches throttle lever tang and the throttle lever cam tainer. Compress rear servo spring and retainer with
touches gauge tool. Compressor Tool C-3422-B or a large C-clamp.
The kickdown valve spring must be fully com (2) Install front servo piston, spring and rod guide.
pressed and the kickdown valve completely bot Compress front servo rod guide with Valve Spring
tomed to obtain correct adjustment. Compressor C-3422-B and install servo snap ring.
(3) Examine bolt holes in overrunning clutch cam.
TRANSMISSION ASSEMBLY AND ADJUSTMENT Note that one hole is not threaded (Fig. 114). This
Assembly Tips hole must align with blank area in clutch cam bolt
Do not allow dirt, grease, or foreign material to en circle (Fig. 115).
ter the case or transmission components during as-
CLUTCH NON-THREADED (10) Install rear band reaction pin (Fig. 116).Be
CAM HOLE sure pin is fully seated in case.
ALIGNMENT OVERRUNNING
MARKS CLUTCH
(FOR N O N - T H R E A D E D ASSEMBLY
HOLE)
REAR BAND
REACTION
PIN
^9121-141
Fig. 114 Location Of Non-Threaded Hole In Clutch

J9121-272
Cam
y ^ l k f CLUTCH Fig. 116 Overrunning Clutch And Rear Band Pin
N i
N ~ 7 CAM
U SEAT Installation
\ ( I N CASE)
(11) Install rear band in case (Fig. 117). Twin lugs
on band seat against reaction pin and single lug
faces band lever.
(12) Install low-reverse drum as follows (Fig. 117):
(a) Lubricate overrunning clutch race (on hub of
drum) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start clutch race into
overrunning clutch rollers.
NON-THREADED
H O L E I N CLUTCH (d) Rotate drum in clockwise direction and push
CAM A L I G N S drum inward until it seats in overrunning clutch.
H E R E (BLANK AREA)
OF SEAT J9121-142
Fig. 115 Location Of Blank Area In Clutch Cam Seat

(In Case)
(4) Mark location of non threaded hole in clutch
cam and blank area of case with paint stripe or
grease pencil (Fig. 116).
(5) Install overrunning clutch roller and spring as
sembly in clutch cam (Fig. 116).
(6) Align and install overrunning clutch in case
(Fig. 116). Be sure cam is correctly installed. Bolt
holes in cam are slightly countersunk on one
side. This side of cam faces rearward (toward
rear support).
(7) Verify that non threaded hole in clutch cam is
properly aligned (Fig. 116). Check alignment by
Fig. 117 Installing Rear Band And Low-Reverse
threading a clutch cam bolt into each hole. Adjust
Drum
cam position if necessary before proceeding.
(8) Install clutch cam bolts. Note that cam bolts (13) Install rear band lever and pivot pin (Fig.
are shorter than rear support bolts. Tighten cam 118). Be sure pin is fully seated in case.
bolts to 17 N T H (150 in. lbs./13 ft. lbs.) torque. (14) Hold low-reverse drum in position and install
(9) Lubricate overrunning clutch rollers with rear support. Align support with punch marks made
transmission fluid. during disassembly.
Fig. 118 Installing Rear Band Lever And Pivot Pin

(15) Install and tighten rear support bolts to 17
Nnn (150 in. lbs. or 13 ft. lbs.) torque.
(16) Install snap ring that retains low-reverse
drum to hub of rear support (Fig. 119).
Fig. 121 Aligning/Seating Rear Planetary In Low-

Reverse Drum
(23) Install governor weight assembly in governor
body. Be sure governor weight snap rings are se
Fig. 119 Installing Low-Reverse Drum Snap Ring curely seated.
(17) Lubricate output shaft, rear support bore and (24) Align and install governor/park gear assembly
low-reverse drum hub with transmission fluid. on output shaft. Note that output shaft in current
(18) Install assembled output shaft and planetary transmission is spotfaced for governor valve end
geartrain in case (Fig. 120). clearance (Fig. 122). Shaft must be indexed so
(19) Align drive lugs on rear planetary gear with that small end of governor valve will seat in this
slots in low-reverse drum (Fig. 121). Then seat plan spotface. Install governor body and park as fol
etary assembly in drum. lows to ensure proper alignment and operation.
(20) Lubricate governor components and park gear (a) Rotate output shaft until spotface (at gover
seal rings with transmission fluid. nor valve shaft hole) is facing upward (Fig. 122).
(21) Install governor filter in park gear and install (b) Position valve bore in governor body over
governor body on gear (Fig. 122). Align governor spotface on output shaft. Then align valve shaft
body on gear using marks made at disassembly. holes in governor body and output shaft.
(22) Install new seal rings on hub of park gear (c) Align splines in output shaft and park gear
(Fig. 123). Be sure ring (or rings) with hooked ends hub.
are properly connected.
(d) Carefully push assembly into place in rear

support (Fig. 123).
(e) Verify that governor valve shaft holes in out
put shaft and governor body are still in alignment.
Reposition governor body and park gear if align
ment is not correct.
(f) Tighten bolts attaching governor body to park
gear to 11 N»m (95 in. lbs.) torque.
SHAFT
Fig. 124 installing Governor Valve And Shaft
J9221-52
Fig. 122 Governor Valve And Output Shaft Spotface

Alignment
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
Fig. 125 Securing Governor Valve Shaft
Fig. 123 Installing Governor Body And Park Gear

(25) Install first E-clip on governor valve shaft.
Then install governor valve and shaft in governor
body (Fig. 124). Be sure valve shaft moves freely
in valve and in output shaft. If valve shaft binds,
governor/park gear is misaligned.
(26) Rotate output shaft until opposite end of gov
ernor valve shaft is facing upward. Then install re
Fig. 126 Installing Governor Body Snap Ring
maining E-clip on governor valve shaft (Fig. 125). Be
very sure both E-clips are firmly seated on shaft. (28) Install output shaft thrust plate on shaft hub
(27) Install snap ring that retains governor body (Fig. 127). Use petroleum jelly to hold thrust plate in
on output shaft (Fig. 126). place.
Fig. 127 installing Output Shaft Thrust Plate Fig. 129 Assembling Front And Rear Clutch Units
(29) Check input shaft seal rings (Fig. 128). Verify
that diagonal-cut ends of teflon seal ring are properly
joined and ends of metal ring are correctly hooked to
gether. Also be sure rings are installed sequence
shown.
Fig. 130 Installing Output Shaft Thrust Washer
Fig. 128 Input Shaft Seal Ring Location

(30) Check rear clutch thrust washer. Use addi
tional petroleum jelly to hold washer in place if nec
essary.
(31) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 129). Rotate front
clutch retainer back and forth until completely
seated on rear clutch.
(32) Coat output shaft thrust washer with petro
leum jelly. Then install washer in rear clutch hub
(Fig. 130). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer Fig. 131 Aligning Rear Clutch Disc Lugs
faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in (34) Raise front end of transmission upward as far
clutch hub. as possible and support case with wood blocks. Front/
(33) Align drive teeth on rear clutch discs with rear clutch and oil pump assemblies are easier to in
small screwdriver (Fig. 131). This will make installa stall if transmission is as close to upright position as
tion on front planetary easier. possible.
(35) Install front and rear clutch units as assembly (39) Install front band lever, strut, lever pin and
(Fig. 132). Align rear clutch with front annulus gear adjusting screw (Fig. 134).
and install assembly in driving shell. Be sure out (40) Tighten front band adjusting screw until band
put shaft thrust washer and thrust plate are not just grips clutch retainer. Verify that front/rear
displaced during installation. clutches are still seated before continuing.
(36) Carefully work assembled clutches back and
BAND BAND
forth to engage and seat rear clutch discs on front
annulus gear. Verify that front clutch drive lugs are
fully engaged in slots of driving shell after installa
tion.
Fig. 134 Front Band Linkage Installation

(41) Coat band lever pin access plug with sealer
and install plug in converter housing (Fig. 135).
J9121-124
Fig. 132 Installing Front/Rear Clutch Assemblies

(37) Slide front band over front clutch retainer
(Fig. 133).
(38) Insert front band reaction pin part way into
Fig. 135 Installing Front Band Reaction Pin Access
case (Fig. 133).
Plug
(42) Check reaction shaft support hub. Verify that
seal rings are hooked together and that front clutch
thrust washer is properly positioned (Fig. 136). Use
extra petroleum jelly to hold thrust washer in place
if necessary.
(43) Thread two Pilot Stud Tools C-3288-B into
bolt holes in oil pump flange (Fig. 126).
(44) Align and install oil pump gasket (Fig. 137).
(45) Lubricate oil pump seals with transmission
fluid, Ru-Glyde, or Door Eze.
(46) Install oil pump (Fig. 138). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install two or three pump bolts to hold pump in
place.
Fig. 133 Installing Front Band And Reaction Pin (47) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N-m (15 ft-lbs).
RINGS J9121-194
Fig. 136 Reaction Shaft Support Seal Rings And

Front Clutch Thrust Washer Position
Fig. 138 Installing Oil Pump And Reaction Shaft

Support
Fig. 137 Installing Pilot Studs And Oil Pump Gasket Fig. 139 Checking Input Shaft End Play
(48) Measure input shaft end play (Fig. 139). At
tach dial indicator to converter housing. Position in
dicator plunger against input shaft and zero
indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.). I f end play is incorrect, transmission is in
correctly assembled, or output shaft thrust washer
and/or thrust plate are worn and need to be changed.
(49) Make sure neutral switch has not been in
stalled in case. Remove switch i f necessary as it will
interfere with valve body installation.
(50) Install new seal rings on accumulator piston Fig. 140 Installing Accumulator Piston And Spring
(Fig. 140). Lubricate accumulator piston, seals and
accumulator bore with transmission fluid. (53) Position valve body on case. Work park rod
past sprag and install valve body-to-case bolts finger
(51) Install accumulator piston and spring (Fig.
tight.
140) in case.
(54) Install park/neutral position switch in case.
(52) Place valve body manual lever in low to move
Tighten switch to 34 N*m (25 ft. lbs.) torque.
park lock rod rearward.
(55) Align valve body on case (Fig. 141). Tighten (59) Adjust front/rear bands as follows:
valve body-to-case bolts alternately and evenly to 12 (a) Loosen locknut on each band adjusting screw
N*m (105 in. lbs.) torque, Start at center and work 4-5 turns.
outward when tightening bolts. Do not overtighten (b) Tighten both adjusting screws to 8 N*m (72
valve body bolts. This could result in distortion in. lbs.).
and cross leakage after installation.. (c) Back off front band adjusting screw 2-1/2
VALVE
turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw in position and
tighten locknuts to 34 N*m (25 ft. lbs.).
(60) Install new pan gasket on transmission and
install oil pan. Tighten pan bolts to 17 N*m (13 ft.
lbs.).
(61) Turn transmission over.
(62) Install new manual lever shaft seal in case.
Use 15/16 deep well socket to install seal.
(63) Install throttle valve and manual valve levers
on shaft.
(64) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated. Be sure converter hub
slots are fully seated in oil pump gear lugs.
(65) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping or small
C-clamp to hold converter in place. Attach strapping
or clamp to converter housing.
Fig. 141 Valve Body Installation
(56) Install new filter on valve body. Tighten filter CAUTION: T h e transmission cooler and lines
screws to 4 N*m (35 in. lbs.). must be reverse flushed if overhaul corrected a
(57) If equipped, position new adapter housing gas malfunction that generated s l u d g e , metal particles,
ket on transmission case. Use petroleum jelly to hold or clutch friction material. T h e torque converter
gasket in place. should also be replaced if contaminated by the
(58) Install adapter housing on transmission case. same m a l f u n c t i o n . D e b r i s and r e s i d u e n o t f l u s h e d
Tighten housing fasteners to 33 N*m (24 ft. lbs.). Be from t h e cooler and lines will flow back into the
sure park lock rod is properly engaged in sprag be t r a n s m i s s i o n and converter. T h e result could be a
fore tightening fasteners. repeat failure a n d s h o p comeback.
J AW-4 AUTOMATIC TRANSMISSION 21 - 147
AW-4 AUTOMATIC TRANSMISSION
CONTENTS
page page
AW-4 IN-VEHICLE SERVICE .... 164 AW-4 TRANSMISSION REMOVAL AND

AW-4 TRANSMISSION DIAGNOSIS 158 INSTALLATION 180
AW-4 TRANSMISSION OVERHAUL 183 GENERAL INFORMATION 147
GENERAL INFORMATION
INDEX
page page
Components and Operation 148 Hydraulic System 150
Description 147 Torque Converter 148
First—Third—Reverse Gear Components 149 Transmission Identification 148
Fourth Gear Overdrive Components . 149 Transmission Ranges and Shift Lever Positions . 147
Geartrain Operation and Application Charts . . . . 150
DESCRIPTION The valve body solenoids are controlled by signals

The AW-4 is a 4-speed, electronically controlled au from a transmission control module (TCM). Signal
tomatic transmission (Fig. 1). Running gear consists sequence is determined by vehicle speed and throttle
of a torque converter, oil pump, three planetary gear position.
sets, clutch and brake units, hydraulic accumulators, Fourth gear is an 0.75:1 ratio overdrive range.
a valve body with electrical solenoids and a trans First, second, third and reverse gear are conventional
mission control module (TCM). The AW-4 is used in ranges. Third gear ratio is 1:1. A separate planetary
XJ models. gear set provides overdrive operation in fourth gear.
Cables are used for shifting and transmission
TRANSMISSION RANGES AND SHIFT LEVER
throttle pressure control. A park/neutral position
POSITIONS
switch permits engine starting in Park and Neutral
The AW-4 transmission has six ranges and shift le
range only. ver positions. Park, Reverse and Neutral are conven-
J8921-398
Fig. 1 AW-4 Automatic Transmission

21 - 148 AW-4 AUTOMATIC TRANSMISSION J
tional and mechanically operated. The 1-2, 3 and D control module (TCM), valve body solenoids and var
ranges provide electronically controlled shifting. ious sensors. The sensors monitor vehicle speed,
The 1-2 position provides first and second gear throttle opening, shift lever position and brake pedal
only. The 3 position provides first, second and third application.
gear. The D range provides first through fourth gear.
Overdrive fourth gear range is available only with TRANSMISSION CONTROL MODULE (TCM)
the shift lever in D position (Fig. 2). The module determines shift and converter clutch
engagement timing based on signals from the sen
sors. The valve body solenoids are activated, or deac
PARK
tivated accordingly.
The module has a self diagnostic program. Compo
nent and circuitry malfunctions can be diagnosed
REVERSE
with the DRB II scan tool. Once a malfunction is
noted and stored in control module memory, it is re
NEUTRAL tained even after the problem has been corrected. To
cancel a stored malfunction, simply disconnect and
FIRST T H R O U G H F O U R T H
reconnect the "Trans." fuse in the module harness.
GEAR ( F O U R T H GEAR
OVERDRIVE) TRANSMISSION VALVE BODY SOLENOIDS
The solenoids are mounted on the valve body and
T H I R D GEAR (MANUAL) operated by the transmission control module. The so
lenoids control operation of the converter clutch and
shift valves in response to input signals from the
FIRST-SECOND GEAR module.
(AAANUAL)
SENSORS
J8921-399 The sensors include the throttle position sensor
(TPS), transmission output speed sensor, vehicle
F i g . 2 AW-4 Shift Lever Positions And Transmission speed sensor, park/neutral position switch and brake
Ranges switch.
TRANSMISSION IDENTIFICATION The throttle position sensor is mounted on the
The transmission I.D. plate is attached to the case throttle body. It electronically determines throttle po
(Fig. 3). The plate contains the transmission serial sition and relays this information to the transmission
and model numbers. Refer to the information on this control module to determine shift points and con
plate when ordering service parts. verter clutch engagement.
The transmission speed sensor consists of a rotor
TRANSMISSION
I.D. PLATE
and magnet on the transmission output shaft and a
switch in the extension housing or adapter. The sen
sor switch is activated each time the rotor and mag
net complete one revolution. Sensor signals are sent
to the transmission control module.
The park/neutral position switch is mounted on the
valve body manual shaft. The switch signals shift
linkage and manual valve position to the transmis
sion control module through an interconnecting har
ness. The switch prevents engine starting in all
gears other than Park or Neutral.
The brake switch is in circuit with the torque con
verter clutch solenoid. The switch disengages the
J8921-400
converter clutch whenever the brakes are applied.
F i g . 3 Transmission Identification The switch is mounted on the brake pedal bracket
and signals the transmission control module when
COMPONENTS AND OPERATION the pedal is pressed or released.
ELECTRONIC CONTROLS TORQUE CONVERTER
The AW-4 is electronically controlled in the 1, 2, 3 A four element torque converter is used for all ap
and D ranges. Controls consist of the transmission plications. The converter consists of the front cover
J AW-4 AUTOMATIC TRANSMISSION 21 - 149
and pump, stator, turbine, and an electronic modu pressure to the clutch through the relay valve at
lated converter clutch mechanism. clutch engagement speeds.
The converter clutch mechanism consists of a slid Torque converter clutch engagement occurs in sec
ing clutch piston, clutch springs and the clutch disc ond gear in 1-2 position; third gear in 3 position and
material (Fig. 4). The clutch provides optimum third and fourth gear in D position.
torque transfer and economy when engaged.
FOURTH GEAR OVERDRIVE COMPONENTS
CLUTCH
The overdrive system consists of the input shaft,
one-way clutch, planetary sun gear, ring gear, plan
etary carrier, direct clutch and overdrive brake (Fig.
5). The overdrive elements are controlled and applied
through transmission valve body solenoid number
two.
In overdrive fourth gear, the brake prevents the
overdrive sun gear from turning. During operation,
the overdrive elements operate as follows:
The overdrive input shaft and planetary carrier ro
tate as a unit. The sun gear and overdrive direct
clutch drum are in mesh and operate as a single
unit. The direct clutch splines function as the hub for
the overdrive brake. The one-way clutch outer race is
in mesh with the planetary carrier. The inner race is
fixed to the sun gear shaft.
FIRST-THIRD-REVERSE GEAR COMPONENTS

First, third and reverse gear components are out
J8921-401 lined in Figure 6.
The input shaft is meshed with the direct clutch
Fig. 4 Torque Converter With Modulated Clutch
hub and the forward clutch drum. These elements ro
The clutch disc is attached to the converter front tate as a unit. The forward clutch hub rotates as a
cover. The clutch piston and clutch springs are at unit with the front planetary ring gear. The direct
tached to the turbine hub. The springs dampen en clutch drum is meshed with the forward end of the
gine firing impulses and loads during the initial planetary sun gear.
phase of converter clutch engagement. The second brake hub serves as the outer race of
Clutch engagement is controlled by transmission one-way clutch No. 1. The clutch inner race is locked
valve body solenoid number three and by the con with the front/rear sun gear. The inner race of one
verter clutch relay valve. The solenoid channels line way clutch No. 2 is splined to the transmission case
DIRECT
CLUTCH OVERDRIVE
CLUTCH CARRIER
J8921-402
Fig. 5 Fourth Gear Overdrive Components

DIRECT FRONT PLANETARY FIRST/REVERSE REAR PLANETARY CARRIER

2ND COAST BRAKE CLUTCH RING GEAR BRAKE
REAR PLANETARY
SECOND BRAKE \ / RING GEAR
OUTPUT SHAFT
FRONT & REAR
PLANETARY
INPUT S H A F T ONE-WAY CLUTCH NO. 2 S U N GEAR J8921-403
Fig. 6 First, Third And Reverse Gear Components

and is locked. The outer race rotates as a unit with The Component Function Chart (Fig. 7) describes
the rear planetary carrier. basic function of various geartrain elements. The
The rear planetary ring gear is splined to the out Component Application Chart (Fig. 8) indicates
put shaft. The front planetary carrier and rear car which elements (including valve body solenoids), are
rier ring gear are meshed and rotate as a unit with applied in the various gear ranges.
the output shaft.
HYDRAULIC SYSTEM
GEARTRAIN OPERATION AND APPLICATION The basic hydraulic system consists of the oil
CHARTS pump, valve body and solenoids and four hydraulic
Operation and application of the first through accumulators. The oil pump provides the necessary
fourth and reverse gear elements are outlined in the system lubrication and operating pressure.
function and application charts. The valve body controls application of the clutches,
brakes, second coast band and the torque converter
NOMENCLATURE FUNCTION
Overdrive Direct Clutch Connects overdrive sun gear and overdrive carrier
Overdrive Brake Prevents overdrive sun gear from turning either clockwise or counterclockwise
Overdrive One-Way Clutch When transmission is driven by engine, connects overdrive sun gear and overdrive carrier
Forward Clutch Connects input shaft and front ring gear
Direct Clutch Connects input shaft and front and rear sun gear
Second Coast Brake Prevents front and rear sun gear from turning either clockwise or counterclockwise
Second Brake Prevents outer race of No. 1 one-way clutch from turning either clockwise or counterclockwise,
thus preventing front and rear sun gear from turning counterclockwise
First/Reverse Brake Prevents rear planetary carrier from turning either clockwise or counterclockwise
One-Way Clutch No. 1 When second brake is operating, prevents front and rear sun gear from turning counterclockwise
One-Way Clutch No. 2 Prevents rear planetary carrier from turning counterclockwise
J8921-404
Fig. 7 Component Function Chart

J AW-4 AUTOMATIC TRANSMISSION 21-151
OVERDRIVE
OVERDRIVI
2x
ONE-WAY
E.
SECOND
Sfil
SECOND
CLUTCH
CLUTCH
CLUTCH
DIRECT
BRAKE
COAST
BRAKE
Valve Body Valve Body
Shift laver
Position
dear Solenoid Solenoid
P *< sgi ii i
No.l No.2
I'
P Park ON OFF
R Reverse ON OFF • • • •
N Neutral ON OFF •
First ON OFF * • • •
D
Second ON ON • • • •
Third OFF ON • • • • •
OD OFF OFF • • • m
First ON OFF • • • •
3 Second ON ON • m • • • •
Third OFF ON « • • m
•
1-2
First ON OFF • • • • •
Second ON ON • • • m
• •
• = Applied J8921-405
Fig. 8 Component Application Chart

clutch. The valve body solenoids control sequencing UPPER
UPPER
of the 1-2, 2-3 and 3-4 shift valves within the valve BODY
GASKET
body. The solenoids are activated by signals from the SEPARATOR
transmission control module. PLATE
The accumulators are used in the clutch and brake
feed circuits to control initial apply pressure. Spring
loaded accumulator pistons modulate the initial
surge of apply pressure for smooth engagement.
OIL PUMP
A gear-type oil pump is used. The pump gears are
mounted in the pump body. The pump drive gear is
operated by the torque converter hub. Drive tangs on
the hub engage in drive slots in the drive gear.
LOWER
TRANSMISSION VALVE BODY COMPONENTS GASKET
Transmission operating pressure is supplied to the
clutch and brake apply circuits through the trans
mission valve body. The valve body consists of an up LOWER
BODY
per body, lower body, separator plate and upper and
J8921-406
lower gaskets (Fig. 9). The various spool valves,
sleeves, plugs and springs are located within the two Fig. 9 Two-Section Transmission Valve Body
body sections.
The manual valve, 1-2 shift valve, primary regula
tor valve, accumulator control valve, check balls, so
lenoids and oil strainers are located in the lower
body section (Fig. 10). The remaining control and
shift valves plus check balls and one additional oil
strainer are located in the upper body section (Fig.
11).
LOWER
BODY
ACCUMULATOR
CONTROL VALVE
1-2 S H I F T VALVE
PRIMARY
REGULATOR VALVE
AAANUAL VALVE
J8921-407
Fig. 10 Upper Body Components
THROTTLE C A M D O W N S H I F T PLUG
SECONDARY REGULATOR VALVE

3-4 SHIFT VALVE
2-3 S H I F T VALVE
LOCK-UP RELAY VALVE

SECOND COAST
M O D U L A T O R VALVE
LOW COAST
UPPER
MODULATOR VALVE
BODY
CUT-BACK VALVE
THROTTLE VALVE J8921-408
1y Components
Fig. 11 Lower I
Manual Valve engagement. At light load, the valve decreases line
The manual valve is operated by the gearshift link pressure just enough to maintain smooth engage
age. The valve diverts fluid to the apply circuits ac ment.
cording to shift lever position.
Throttle Valve and Downshift Plug
Primary Regulator Valve The throttle valve and downshift plug (Fig. 14)
The primary regulator valve (Fig. 13) modulates control throttle pressure to the primary regulator
line pressure to the clutches and brakes according to valve.
engine load. The valve is actuated by throttle valve The downshift plug and throttle valve are operated
pressure. by the throttle valve cam and throttle cable in re
During high load operation, the valve increases sponse to engine throttle position. Throttle valve
line pressure to maintain positive clutch and brake pressure is also modulated by the cut-back valve in
second, third and fourth gear ranges.
4 AW-4 AUTOMATIC TRANSMISSION 21-153
D, 3 , 1 - 2 R A N G E LINE PRESSURE
CABLE
LINE PRESSURE
(FROM OIL PUMP)
THROTTLE
VALVE
t 1-2 CAM
RANGE
DOWNSHIFT
PLUG
CUT-BACK PRESSURE
(FROM CUT-BACK
DRAIN VALVE)
THROTTLE
VALVE
3 O R 1-2
RANGE
LINE
PRESSURE
J8921-409
Fig. 12 Manual Valve
THROTTLE PRESSURE
(TO PRIAAARY REGULATOR
VALVE)
THROTTLE PRESSURE
J8921-411
LINE PRESSURE
\ <=» (FROM M A N U A L VALVE Fig. 14 Throttle Valve And Downshift Plug
" R " RANGE)
Secondary Regulator Valve
LINE PRESSURE
(FROM PUMP)
DRAIN
CONVERTER PRESSURE THROTTLE

T O CONVERTER CLUTCH PRESSURE
RELAY VALVE
m+ CUT-BACK
PRESSURE
T O THROTTLE
DRAIN
VALVE
SECOND BRAKE
LINE PRESSURE
CUT-BACK
VALVE
CONVERTER PRESSURE
(TO SECONDARY R E G U L A T O R VALVE) J9321-91
Fig. 13 Primary Regulator Valve

Cut-Back Valve J8921-412
The cut-back valve (Fig. 15) helps prevent exces Fig. 15 Cut-Back Valve
sive pump pressure buildup in second, third and
The secondary regulator valve (Fig. 16) regulates
fourth gear. The valve is actuated by throttle pres
converter clutch and transmission lubrication pres
sure and by line pressure from the second brake. The sure. When primary regulator valve pressure exceeds
valve also helps regulate line pressure by controlling requirements for clutch engagement or transmission
the amount of cut-back pressure to the throttle valve. lubrication, the secondary regulator valve is moved
21-154 AW-4 AUTOMATIC TRANSMISSION
upward exposing the drain port. Excess pressure SOLENOID VALVE N O . 3

then bleeds off as needed. As pressure drops, spring
tension moves the valve downward closing the drain
port.
TO CONVERTER
CLUTCH (ENGAGED)
SECONDARY
REGULATOR
VALVE
T O OIL
COOLER 11
t
LINE PRESSURE
(FROM 1-2 S H I F T
VALVE)
-ft <=> C O N V E R T E R P R E S S U R E
DRAIN TO CONVERTER
CLUTCH DRAIN
(DISENGAGED)
CONVERTER
CLUTCH LINE PRESSURE
RELAY (FROM PUMP)
CONVERTER VALVE
PRESSURE (TO LOCK-UP
J9321-92
RELAY VALVE)
FROM PRIMARY ft Fig. 17 Converter Clutch Relay Valve

REGULATOR
VALVE
valve body solenoid and line pressure from the man
ual valve, second coast modulator valve and the 2-3
Fig. 16 Secondary Regulator Valve shift valve.
Converter Clutch Relay Valve When the transmission control module deactivates
The relay valve (Fig. 17) controls fluid flow to the the solenoid, line pressure at the top of the valve
converter clutch. The valve is operated by line pres moves the valve down closing the second brake accu
sure from the 1-2 shift valve and is controlled by so mulator feed port. As the solenoid is activated and
lenoid valve number three. the drain port opens, spring force moves the valve up
exposing the second brake feed port for the shift to
1-2 Shift Valve second gear.
The 1-2 shift valve (Fig. 18) controls 1-2 upshifts
and downshifts. The valve is operated by the No. 2
LINE PRESSURE
(FROM SOLENOID
VALVE NO. 2) LINE PRESSURE LINE PRESSURE
(FROM AAANUAL ^ (FROM 2-3 SHIFT VALVE)
VALVE IN " D " " 2 "
OR " L " RANGE m> T O 2ND COAST MODULATOR
VALVE
DRAIN
LINE PRESSURE o
(FROM AAANUAL TO ACCUMULATORS A N D
VALVE IN " R " SOLENOID VALVE NO. 3
DRAIN « • RANGE)
T O FIRST/REVERSE ^
BRAKE m> TO FIRST/REVERSE BRAKE
& FROM LOW COAST

MODULATOR
VALVE
LINE PRESSURE
(FROM 2-3 SHIFT VALVE,
IN 3RD OR OD GEAR)
1ST GEAR 2ND GEAR
J8921-415
Fig. 18 1-2 Shift Valve

AW-4 AUTOMATIC TRANSMISSION 21-155
LINE PRESSURE
(FROM SOLENOID
VALVE NO. 1)
LINE PRESSURE LINE PRESSURE
(FROM M A N U A L (FROM AAANUAL
VALVE IN 1 - 2 f*TO!-2 VALVE IN 1-2
POSITION) co" SHIFT POSITION) co-
VALVE
T O 3-4 S H I R VALVE « - ]
LINE PRESSURE
LINE PRESSURE (FROM PRIAAARY T O DIRECT CLUTCH
(FROM PRIMARY REGULATOR VALVE) ACCUMULATOR A N D 1-2
REGULATOR SHIFT VALVE
VALVE)
w T O LOW COAST
~ MODULATOR VALVE
LINE PRESSURE
(FROM AAANUAL o .
VALVE)
2ND GEAR 3RD GEAR
J8921-416

2-3 Shift Valve 3-4 Shift Valve
The 2-3 shift valve (Fig. 19) controls 2-3 upshifts The 3-4 shift valve (Fig. 20) is operated by the No.
and downshifts. The valve is actuated by the No. 1 2 solenoid and by line pressure from the manual
valve body solenoid and by line pressure from the valve, 2-3 valve and primary regulator valve.
manual valve and primary regulator valve. Energizing the No. 2 solenoid causes line pressure
When the transmission control module activates so at the top of the 3-4 valve to be released through the
lenoid No. 1, line pressure at the top of the 2-3 valve solenoid valve drain port. Spring tension moves the
is released through the solenoid drain port. Spring valve up exposing the overdrive clutch accumulator
tension moves the valve up to hold the valve in sec feed port to apply the clutch.
ond gear position. As the solenoid is deactivated, line De-energizing the solenoid causes the drain port to
pressure then moves the valve down exposing the di close. Line pressure then moves the valve down ex
posing the overdrive brake accumulator feed port for
rect clutch feed port for the shift to third gear.
the shift to fourth gear.
LINE PRESSURE
LINE
So (FROM SOLENOID
PRESSURE
T O OVERDRIVE CLUTCH VALVE NO.2)
ACCUMULATOR
LINE PRESSURE
(FROM PRIAAARY
REGULATOR
VALVE)
LINE PRESSURE
(FROM PRIAAARY
REGULATOR VALVE) T O OVER DRIVE BRAKE
ACCUMULATOR
LINE PRESSURE
(FROM 2-3 SHIFT
VALVE)
3RD GEAR 4 T H GEAR
OVERDRIVE
J8921-417

21-156 AW-4 AUTOMATIC TRANSMISSION J
In the 1-2 or 3 gearshift lever positions, line pres

sure from the 2-3 shift valve is applied to the lower
end of the 3-4 valve. This holds the valve upward, LINE PRESSURE
closing off the overdrive brake feed port preventing a (FROM 2-3
shift into fourth gear. SHIFT VALVE)
Second Coast Modulator Valve

The second coast modulator valve (Fig. 21) momen LOW COAST yf
tarily reduces line pressure from the 1-2 shift valve. MODULATOR'
PRESSURE T O
This cushions application of the second coast brake.
FIRST/REVERSE
The valve is operative when the shift lever and man BRAKE
ual valve are in the 3 position.
lap LINE PRESSURE

(FROM 1-2 SHIFT
VALVE)
J8921-419
• Fig. 22 Low Coast Modulator Valve

LOW COAST
MODULATOR
PRESSURE
SECOND
COAST BRAKE
LINE PRESSURE ^ H i
(FROM PUMP)
ACCUMULATOR
CONTROL
J8921-418 PRESSURE (TO
ACCUMULATORS)
Fig. 21 Second Coast Modulator Valve
Low Coast Modulator Valve
The low coast modulator valve (Fig. 22) momen C=> THROTTLE
PRESSURE
tarily reduces line pressure from the 2-3 shift valve
to cushion application of the first/reverse brake. The
valve operates when the shift lever and manual
valve are in the 1-2 position.
J8921-420
Accumulator Control Valve

Fig. 23 Accumulator Control Valve
The accumulator control valve (Fig. 23) cushions
clutch and brake application by reducing back pres side of the accumulator pistons. This pressure plus
sure to the accumulators when throttle opening is spring tension holds the pistons down. As line pres
small. The valve is operated by oil pump (line) pres sure from the shift valves enters the opposite end of
the piston bore, control pressure and spring tension
sure and by throttle pressure.
momentarily delay application of full line pressure to
Accumulators
cushion engagement. The accumulators are all lo
cated in the transmission case (Fig. 24).
Four accumulators are used to cushion application
of the clutches and brakes (Fig. 24). The accumula
tors consist of spring loaded pistons which dampen
the initial surge of apply pressure to provide smooth
engagement during shifts.
Control pressure from the accumulator control
valve is continuously applied to the back pressure
tl AW-4 AUTOMATIC TRANSMISSION 21 - 157
OVERDRIVE releasing line pressure. The signal to apply or re

CLUTCH lease pressure is provided by the transmission con
trol module.
The No. 3 solenoid controls operation of the torque
converter clutch. The solenoid operates in response to
signals from the transmission control module.
When the No. 1 and 2 solenoids are activated, the
solenoid plunger is moved off its seat opening the
drain port to release line pressure. When either sole
noid is deactivated, the plunger closes the drain port.
The No. 3 solenoid operates in reverse. When the
solenoid is deactivated, the solenoid plunger is moved
off its seat opening the drain port to release line
pressure. When the solenoid is activated, the plunger
closes the drain port.
J9121-375
Fig. 24 Accumulators
Transmission Valve Body Solenoids
Three solenoids are used (Fig. 2 5 ) . The No. 1 and 2
solenoids control shift valve operation by applying or
LINE PRESSURE
J8921-422
Fig. 25 Transmission Valve Body Solenoids

21-158 AW-4 TRANSMISSION DIAGNOSIS J
AW-4 TRANSMISSION DIAGNOSIS
INDEX
page page
General Diagnosis Information 158 Preliminary Inspection and Adjustment 159
Hydraulic Pressure Test 159 Time Lag Test . 160
Manual Shifting Test 159 Torque Converter Stall Test 160
GENERAL DIAGNOSIS INFORMATION Diagnosis should begin with the Preliminary In
Shift points are controlled by the transmission con spection And Adjustment procedure. It is will help
trol module (TCM). Before attempting repair, deter determine if a problem is mechanical or electrical.
mine if a malfunction is electrical or mechanical. The first procedure step is Initial Inspection and Ad
The TCM used with the AW-4 transmission has a justment.
self-diagnostic program compatible with the DRB II
scan tool. The tester will identify faults in the elec
trical control system.
PERFORM INITIAL INSPECTION REPAIR OR

A N D ADJUSTAAENT REPLACE
N O T O K
PROCEDURE OUTLINED I N — C O M P O N E N T S AS
T H I S SECTION NEEDED
PERFORM AAANUAL SHIFTING NOT OK •

TEST
C O N N E C T DRBII™ T E S T E R .
PERFORM TEST PROCEDURE
OUTLINED IN TESTER AAANUAL.
ELECTRICAL CONTROL PERFORM HYDRAULIC

S Y S T E M CHECK PRESSURE T E S T , STALL TEST
A N D TIAAE LAG TEST
NOT OK
REPAIR O R REPLACE PROBLEM REPAIR TRANSMISSION A S

COMPONENTS NECESSARY
J8921-423
Fig. 26 Preliminary Diagnosis Check Procedure

J AW-4 TRANSMISSION DIAGNOSIS 21 - 159
PRELIMINARY INSPECTION AND ADJUSTMENT HYDRAULIC PRESSURE TEST

(1) Check and adjust transmission shift cable if
PRESSURE TEST PROCEDURE
necessary.
(2) Verify transmission throttle cable operation. (1) Connect pressure test gauge to test port on pas
Repair or replace cable if necessary. senger side of transmission. Use Adapter 7554 to
(3) Check engine throttle operation. Operate accel connect gauge. Be sure test gauge has minimum ca
erator pedal and observe injector throttle plate move pacity of 300 psi (2100 kPa).
ment. Adjust linkage if throttle plate does not reach (2) Be sure transmission fluid is at normal operat
wide open position. ing temperature.
(4) Check transmission fluid level when fluid is at PRESSURE T E
ST
normal operating temperature. Start engine. Shift
transmission through all gear ranges then back to
Neutral. Correct level is to Full or Add mark on dip
stick with engine at curb idle speed.
(5) Check and adjust park/neutral position switch
if necessary.
(6) Check throttle position sensor adjustment and
operation. Adjust the sensor if necessary.
MANUAL SHIFTING TEST

(1) This test determines if problem is related to
mechanical or electrical component.
(2) Stop engine and disconnect transmission con
trol module or module fuse.
(3) Road test vehicle. Shift transmission into each
gear range. Transmission should operate as follows:
• lock in Park
• back up in Reverse
• not move in Neutral J8921-424
• provide first gear only with shift lever in 1-2 posi Fig. 27 Pressure Test Gauge Connection
tion
• operate in third gear only with shift lever in 3 po (3) Apply parking brakes and block wheels.
sition
WARNING: DO N O T A L L O W ANYONE T O S T A N D
• operate in overdrive fourth gear in D position
AT T H E F R O N T OR R E A R OF T H E VEHICLE W H I L E
(4) If transmission operates as described, proceed
P E R F O R M I N G T H E FOLLOWING S T E P S IN T H E
to next step. However, if forward gear ranges were
PRESSURE TEST.
difficult to distinguish (all feel the same), or vehicle
would not back up, refer to diagnosis charts. Do not (4) Check and adjust engine curb idle speed.
perform stall or time lag tests. (5) Apply service brakes.
CAUTION: Do not overspeed the engine during (6) Shift transmission into D range and note line
the next test step. Ease off the throttle and allow pressure with engine at curb idle speed. Pressure
the vehicle to slow before downshifting. should be 61-to-70 psi (421-to-481 kPa).
(7) Press accelerator pedal to wide open throttle
(5) Continue road test. Manually downshift trans position and note line pressure. Pressure should be
mission from D to 3, and from 3 to 1-2 position. Then 173-to-209 psi (1196-to-1442 kPa).
manually upshift transmission through forward
ranges again. CAUTION: Do not maintain wide open throttle for
(6) If transmission operation is OK, perform stall, more than three or four seconds at a time.
time lag and pressure tests. If transmission shifting
(8) Shift transmission into Reverse and note line
problem is encountered, refer to diagnosis charts.
pressure with engine at curb idle speed. Pressure
(7) If a problem still exists, continue testing with
should be 75-to-90 psi (B19-to-618 kPa).
DRB II scan tool.
(9) Press accelerator to wide open throttle position
and note line pressure in Reverse. Pressure should be
21340-263 psi (1471-to-1814 kPa).
21 - 180 AW-4 TRANSMISSION DIAGNOSIS J
CAUTION: Do not maintain wide open throttle for (8) Press accelerator pedal to wide open throttle
more than three or four seconds at a time. position and note maximum engine rpm. Stall speed
should be 2100 to 2400 rpm in D range.
(10) If line pressure is not within specifications,
adjust transmission throttle cable and repeat pres CAUTION: Do not maintain wide open throttle f o r
sure test. more than 3-4 seconds at a time.
PRESSURE TEST ANALYSIS (9) Release throttle and shift transmission into
If pressures in D and Reverse are higher than spec Neutral. Allow transmission fluid to cool for 15-20
ified, check for the following: seconds.
• throttle cable loose, worn, binding or out of adjust (10) Shift transmission into Reverse.
ment (11) Press accelerator down to wide open throttle
• throttle valve, downshift plug, throttle cam, or pri position and note maximum engine rpm. Stall speed
mary regulator valve are sticking, worn or damaged should be 2100-to-2400 rpm in Reverse.
If pressures in D and Reverse are lower than spec
ified, check for following: STALL SPEED TEST ANALYSIS
• throttle cable loose, worn, binding or out of adjust If engine rpm is lower than specified in D and Re
ment verse, check for the following:
• throttle valve, downshift plug, throttle cam stick • engine output/performance insufficient
ing, worn or damaged • stator overrunning clutch in torque converter not
• primary regulator valve sticking, worn, or dam holding if engine speed was 1500 rpm or less.
aged If stall speed in D range is higher than specified,
• oil pump gears or housing worn or damaged check for the following:
• overdrive clutch worn or damaged • line pressure low
If pressures are low in D range only, check for fol • forward clutch slipping
lowing: • No. 2 one-way clutch not holding
• overdrive one-way clutch not holding
• forward clutch worn or damaged
If stall speed in Reverse was higher than specified,
• fluid leakage in D range circuit (component seal
check for the following:
and O-rings)
• line pressure low
If pressures are low in Reverse only, check for fol
• direct clutch slipping
lowing:
• first/ reverse >rake slipping
• shift cable and manual valve out of adjustment • overdrive one-way clutch not holding
• fluid leakage in reverse circuit (component seal If stall speeds were higher than specified in both D
and O-rings) and Reverse, check for the following:
• direct clutch worn or damaged • low fluid level
• first/reverse brake worn or damaged • line pressure low
• overdrive one-way clutch not holding
TORQUE CONVERTER STALL TEST
Stall testing checks the holding ability of the TIME LAG TEST
transmission clutches and brakes and of the torque This test checks general condition of the overdrive
converter stator overrunning clutch. clutch, forward clutch, rear clutch and first/reverse
(1) Be sure transmission fluid is at normal operat brake. Condition is indicated by the amount of time
ing temperature. required for clutch/brake engagement with the en
(2) Connect tachometer to engine. Position tachom gine at curb idle speed. Engagement time is mea
eter so it can be viewed from drivers seat. sured for D and Reverse positions. A stop watch is
(3) Apply parking brakes and block wheels. recommended for test accuracy.
(4) Apply and hold service brakes.
(5) Shift transfer case into 2H position. On models TEST PROCEDURE
with NP249 transfer case, leave transfer case in 4H (1) Check and adjust transmission fluid level if
position. necessary.
(2) Bring transmission to normal operating tem
(6) Start engine.
perature.
WARNING: DO N O T A L L O W ANYONE T O S T A N D (3) Apply parking brakes and turn off air condi
AT T H E FRONT OR REAR OF T H E VEHICLE DUR tioning unit.
ING T H E T E S T . (4) Shift transfer case into 2H range. On models
with NP249 transfer case, leave transfer case in 4H
(7) Shift transmission into D range. range.
J AW-4 TRANSMISSION DIAGNOSIS 21-161
(5) Start engine and check curb idle speed. Adjust TIME LAG TEST ANALYSIS
speed if necessary. Curb idle must be correct to en If engagement time is longer than specified for D
sure accurate test results. range, check for the following:
(6) Shift transmission into Neutral and set stop • shift cable misadjusted
watch. • line pressure low
(7) During following test steps, start stop watch as • forward clutch worn
soon as shift lever reaches D and Reverse ranges. • overdrive clutch worn or damaged
(8) Shift transmission into D range and record If engagement time is longer than specified for Re
time it takes for engagement. Repeat test two more verse, check for the following:
times. • shift cable misadjusted
(9) Reset stop watch and shift transmission back to • line pressure low
Neutral.
• direct clutch worn
(10) Shift transmission into Reverse and record
• first/reverse brake worn
time it takes for engagement. Repeat test two more
• overdrive clutch worn or damaged
times.
(11) Engagement time in D range should be a
maximum of 1.2 seconds. Engagement time for Re
verse should be a maximum of 1.5 seconds.
i
21-162 AW-4 TRANSMISSION DIAGNOSIS J
SERVICE DIAGNOSIS
WILL NOT BACK U P OR

VEHICLE Shift cable out of adjustment or damaged Adjust cable or replace cable
MOVE FORWARD Valve body or primary regulator faulty Inspect/repair valve body
Park lock pawl faulty Repair park pawl
Torque converter faulty Replace torque converter
Converter drive plate broken Replace drive plate
O i l pump intake screen blocked Clean screen
Transmission faulty Disassemble and repair transmission
SHIFT LEVER POSITION Shift cable out o f adjustment Adjust cable

INCORRECT Manual valve and lever faulty Repair valve body
HARSH ENGAGEMENT Throttle cable out of adjustment Adjust throttle cable

Valve body o r primary regulator faulty Repair valve body
Accumulator pistons faulty Repair pistons
DELAYED 1 -2, 2-3 OR 3-4 Electronic control problem Locate problem with D R B II Tester
UP-SHIFT, OR DOWN-SHIFTS Valve body faulty Repair valve body
FROM 4-3 OR 3-2 AND SHIFTS Solenoid faulty Repair solenoid
BACK TO 4 OR 3
SUPS ON 1-2, 2-3 OR 3-4 Shift cable out o f adjustment Adjust cable
UP-SHIFT, OR SLIPS OR Throttle cable out of adjustment Adjust cable
SHUDDERS DURING Valve body faulty Repair valve body
ACCELERATION Solenoid faulty Replace solenoid
DRAG OR BIND ON 1-2, 2-3 Shift cable out of adjustment Adjust cable
O R 3-4 UP-SHIFT Valve body faulty Repair valve body
CONVERTER CLUTCH DOES NOT Electronic control problem Check with D R B II Tester
ENGAGE IN 2ND, 3RD OR 4TH Valve body faulty Repair valve body
Solenoid faulty Replace solenoid
HARSH DOWN-SHIFT Throttle cable out o f adjustment Adjust cable

Throttle cable and cam faulty Replace cable and cam
Accumulator pistons faulty Repair pistons
Valve body faulty Repair valve body
NO DOWN-SHIFT WHEN Valve body faulty Repair valve body

COASTING Solenoid faulty Replace solenoid
Electronic control problem Locate problem with D R B 11 Tester
J9321-93
J AW-4 TRANSMISSION DIAGNOSIS 21 - 163
SERVICE DIAGNOSIS
D O W N - S H I R LATE O R EARLY Throttle cable faulty Replace cable

DURING COAST Valve body faulty Repair valve body
Solenoid faulty Replace solenoid
Electronic control problem Locate problem with D R B II Tester
NO 4-3, 3-2 OR 2-1 Solenoid faulty Replace solenoid

KICKDOWN Electronic control problem Locate problem with D R B II Tester
NO ENGINE BRAKING IN 1 -2 Solenoid faulty Replace solenoid

POSITION Electronic control problem Locate problem with D R B II Tester
VEHICLE DOES NOT HOLD Shift cable out o f adjustment Adjust cable
IN PARK Parking lock pawl cam and spring faulty Replace cam and spring
OVERHEAT DURING NORMAL Low fluid level Add fluid and check for leaks
OPERATION (FLUID
DISCOLORED, SMELLS BURNED) Fluid cooler, lines blocked, o r cooler cracked Flush cooler and lines and replace
(oil in engine coolant) radiator if transmission fluid has
entered coolant
OVERHEAT DURING Vehicle not properly equipped for trailer Be sure vehicle is equipped with
COMMERCIAL OPERATION towing o r commercial use recommended optional components
OR WHILE TRAILER TOWING (i.e., H D springs, transmission, axle,
(FLUID DARK AND BURNED larger CID engine, auxiliary cooler,
WITH SOME SLUDGE correct axle ratio, etc.). If vehicle is not
FORMATION) so equipped, it should not be used for
severe service operation
Vehicle not equipped with auxiliary Drain fluid, change filter, and install
fluid cooler auxiliary cooler
Extensive idling time or operation in heavy Cut down on idlina time; shift into
traffic in hot weather neutral every so often and run engine
at 1 0 0 0 rpm to help circulate fluid
through cooler
T o w vehicle overloaded (exceeding vehicle Be sure vehicle is properly equipped to

tow capacity) handle load; do not tow Class Ill-type
loads with a vehicle that is only rated
for Class 1 or II operation
A i r flow to auxiliary cooler blocked by Remove or reposition item causing

snow plow, front mounted spare tire, Dug air flow blockage
screen, or similar item
OIL COMES OUT FILLER TUBE Transmission overfilled Drain fluid to correct level; remove neutral
switch and drain through switch hole
with suction gun
Breather vent in oil pump blocked Inspect and clear blockage
Fluid cooler or cooler lines plugged Flush cooler and lines
J9321-94
21 - 184 AW-4 IN-VEHICLE SERVICE J
AW-4 1N-WEH1CLE SERWICE
INDEX
page page
Accumulator Pistons, and Springs . 171 Speed Sensor Rotor—Speedometer Drive Gear . 175
Adapter Housing Seal Replacement . . . . . . . . . . 173 Throttle Position Sensor ( T P S ) Service 175
Checking Fluid Level and Condition 164 Transmission Control Module (TCM) Service . . . 164
Manual Valve Shaft Seal Replacement 169 Transmission Cooler Line Fittings 179
Park Interlock Cable Adjustment . 177 Transmission Cooler Service 178
Park Rod and Pawl Service 173 Transmission Throttle Cable Adjustment 176
Park/Neutral Position Switch . . . . . . . . . . . . . . . 164 Transmission Throttle Cable Replacement . . . . . 175
Second Coast Brake Servo 172 Transmission Valve Body Installation 168
Shift Cable Adjustment 176 Transmission Valve Body Removal . . . . . . . . . . 167
Speed Sensor 174 Transmission Valve Body Solenoids . 166
CHECKING FLUID LEVEL AND CONDITION eign material or particles. If the fluid is dark brown
Recommended fluid for AW-4 transmissions is Mo or black in color and smells burnt, the fluid has been
par Mercon automatic transmission fluid. Mopar overheated and should be replaced.
Dexron II may be used if Mercon fluid is not readily Transmission operation should also be checked if
available. the fluid is severely discolored and contains quanti
ties of foreign material, metal particles, or clutch
CHECKING FLUID LEVEL disc friction material.
(1) Be sure transmission fluid is at normal operat A small quantity of friction material or metal
ing temperature. Normal operating temperature is particles in the oil pan is normal. The particles
reached after approximately 15 miles (25 km) of op are usually generated during the break-in pe
eration. riod and indicate normal seating of the various
(2) Position vehicle on level surface. This is impor transmission components.
tant for an accurate fluid level check.
(3) Shift transmission through all gear ranges and TRANSMISSION CONTROL MODULE (TCM)
back to Park. SERVICE
(4) Apply parking brakes. Use the DRB II scan tool to diagnose transmission
(5) Verify that transmission is in Park. control module function whenever a fault is sus
(6) Wipe off dipstick handle to prevent dirt from pected. Replace the module only when actually
entering fill tube. Then remove dipstick and check faulty.
fluid level and condition.
TRANSMISSION CONTROL MODULE
(7) Correct fluid level is to FULL mark on dip
REPLACEMENT
stick when fluid is at normal operating temper
The transmission control module is under the
ature (Fig. 1).
driver side of the instrument panel. It is at the left
(8) If fluid level is low, top off level with Mopar
side of the steering column (Fig. 2).
Mercon. Mopar Dexron II may also be used if Mercon
To remove the module, disconnect the wire har
is not available. Do not overfill transmission. Add
ness, remove the mounting screws and remove the
only enough fluid to bring level to Full mark.
module from the cowl panel (Fig. 2). Tighten the
TRANSMISSION module mounting screws securely after installation.
DIPSTICK Also be sure the wire harness is not twisted, kinked
or touching any body panels.
rADD FULL — CHECK
— OK RANGE
SWITCH TESTING
Test switch continuity with an ohmmeter. Discon
J8921-427 nect the switch and check continuity at the connector
terminal positions and in the gear ranges indicated
Fig. 1 Transmission Fluid Level in Figure 3. Switch continuity should be as follows:
CHECKING FLUID CONDITION • Continuity should exist between terminals B and
Inspect the appearance of the fluid during the fluid C with the transmission in Park and Neutral only
level check. The fluid should be clear and free of for- (Fig. 3).
AW-4 IN-VEHICLE SERVICE 21-165
\ STEERING A D J U S T I N G BOLT
TRANSMISSION COLUMN
CONTROL M O D U L E SUPPORT TABBED
\\\ :
WASHER
~''''' mm
m
J9321-87
Fig. 2 Transmission Control Module Location And

Mounting
• Continuity should exist between terminals A and
ATTACHING
E with the transmission in Reverse (Fig. 3). J8921-430
NUT
• Continuity should exist between terminals A and
G with the transmission in third gear (Fig. 3). Fig. 4 Park/Neutral Position Switch Removal/
• Continuity should exist between terminals A and Installation
H with the transmission in first and/or second gear
(Fig. 3).
INSTALLATION AND ADJUSTMENT
• Continuity should not exist in D position.
(1) Disconnect shift linkage rod from shift lever on
rr a
left side of transmission.
SWITCH (2) Rotate manual shift lever all the way rear
TERMINAL ward. Then rotate lever forward two detent positions
IDENTIFICATION- I E F G H j to Neutral.
I D C
I
B A (3) Install switch on manual valve shaft and in
stall switch adjusting bolt finger tight. Do not
tighten bolt at this time.
(4) Install tabbed washer on manual valve shaft
and install switch attaching nut. Tighten nut to 6.9
#
N m (61 in. lbs.) torque but do not bend washer lock
-O tabs over nut at this time.
(5) Verify that transmission is in Neutral.
(6) Rotate switch to align neutral standard line
with vertical groove on manual valve shaft (Fig. 5).
O (7) Align switch standard line with groove or flat
on manual valve shaft.
1-2 O (8) Tighten switch adjusting bolt to 13 Nnn (9 ft.
lbs.) torque.
J8921-429 (9) Bend at least two washer lock tabs over switch
attaching nut to secure it.
Fig. 3 Park/Neutral Position Switch Terminals And
(10) Connect shift linkage rod to shift lever on left
Testing
side of case.
PARK/NEUTRAL POSITION SWITCH REMOVAL (11) Connect switch wires to harness and lower ve
(1) Raise vehicle. hicle.
(2) Disconnect switch wire harness connector. (12) Check switch operation. Engine should start
(3) Pry washer lock tabs upward and remove in Park and Neutral only.
switch attaching nut and tabbed washer (Fig. 4).
(4) Remove switch adjusting bolt (Fig. 4).
(5) Slide switch off manual valve shaft.
21-168 AW-4 IN-VEHICLE SERVICE J
SOLENOID W I R E
CONNECTORS
NEUTRAL
STANDARD LINE
ADJUSTING
BOLT
VERTICAL
GROOVE
O N AAANUAL
VALVE S H A F T
J8921-431 J8921-433
Fig. 5 Park/Neutral Position Switch Adjustment Fig. 7 Solenoid Wire Connectors

TRANSMISSION VALVE BODY SOLENOIDS VALVE BODY
SOLENOIDS
SOLENOID REMOVAL
(1) Remove transmission oil pan drain plug and
drain fluid.
(2) Remove pan bolts and remove oil pan.
(3) Remove oil screen bolts and remove screen
(Fig. 6) and gasket. Discard the gasket.
OIL OIL
SCREEN SCREEN
BOLTS
J8921-434
Fig. 8 Transmission Valve Body Solenoids

(8) Remove old sealer material from oil pan and
transmission case.
Solenoid Testing
Test solenoid resistance with an ohmmeter. Con
nect the ohmmeter leads to the solenoid mounting
bracket and to the solenoid wire terminal (Fig. 9).
Solenoid resistance should be 11-15 ohms. Replace
Fig. 6 OH Screen Removal/Installation the solenoid if resistance is above or below the spec
ified range.
(4) Disconnect solenoid wire connector (Fig. 7).
(5) If all solenoids are being removed, mark or tag SOLENOID INSTALLATION
wires for assembly reference before disconnecting (1) Position solenoids on valve body and install so
them. lenoid bolts. Tighten bolts to 10 N»m (7 ft. lbs.)
(6) Remove bolt attaching solenoids to valve body torque.
and remove solenoids (Fig. 8). Do not alloW any valve (2) Connect feed wires to solenoids.
body components to fall out when solenoids are re (3) Install new gaskets on oil screen and install
moved. screen. Tighten screen bolts to 10 N*m (7 ft. lbs.)
(7) Clean oil filter and pan with solvent and dry torque.
with compressed air. (4) Apply bead of Three-Bond TB 1281 or equiva-
AW-4 IN-VEHICLE SERVICE 21 - 187
(4) Pull harness adapter and wires out of case.

(5) Remove and discard adapter O-ring.
(6) Lubricate new O-ring and install it on adapter.
(7) Install solenoid wire harness and adapter in
case.
(8) Install adapter bracket and bracket bolt.
(9) Connect wires to solenoids.
(10) Install oil screen and oil pan.
TRANSMISSION VALVE BODY REMOVAL

Removal and installation are the only valve body
service procedures covered in this section. Refer to
the transmission overhaul section for valve body dis
assembly, cleaning, inspection and reassembly.
(1) Remove oil pan plug and drain transmission
fluid.
(2) Remove oil pan and oil screen. Clean pan and
J8921-435 screen in solvent and dry them with compressed air.
(3) Disconnect solenoid wire connectors (Fig. 7).
Fig. 9 Testing Transmission Valve Body Solenoid Mark wires for assembly reference.
lent sealer to oil pan sealing surface. Sealer bead SOLENOID W I R E
should be at least 3.0 mm (1/8 in.) wide. CONNECTORS
(5) Install oil pan on transmission. Tighten pan
bolts to 7 N»m (65 in. lbs.) torque.
(6) Install and tighten oil pan drain plug to 20
N»m (15 ft. lbs.) torque.
(7) Fill transmission with Mopar Mercon or
Dexron II.
SOLENOID HARNESS ADAPTER SEAL

REPLACEMENT
(1) Remove oil pan and oil screen. Refer to Sole
noid Removal procedure.
(2) Disconnect solenoid wire connectors (Fig. 7).
(3) Remove bracket securing solenoid harness
adaptor (Fig. 10) to case.
J8921-433
Fig. 11 Solenoid Wire Connections

(4) Remove valve body oil tubes (Fig. 13). Care
fully pry tubes out of valve body with screwdriver.
(5) Disconnect throttle cable from throttle cam
(Fig. 13).
(6) Remove valve body bolts. Bolt locations are
outlined in Figure 14.
(7) Lower valve body and remove overdrive clutch
accumulator springs, direct clutch accumulator
springs and second brake accumulator spring (Fig.
15)
(8) Remove valve body and check ball and spring
(Fig. 16).
J8921-436
Fig. 10 Harness Adapter Removal/Installation

J8921-439
J8921-437 Fig. 14 Transmission Valve Body Bolt Locations
Fig. 12 Removing Transmission Valve Body Oil

Tubes
OVERDRIVE
CLUTCH DIRECT CLUTCH
ACCUMULATOR ACCUMULATOR
SPRINGS SPRINGS
THROTTLE THROTTLE SECOND BRAKE
CABLE CAM OVERDRIVE ACCUMULATOR
BRAKE SPRING
ACCUMULATOR
J8921-438 SPRING J9121-377
Fig. 13 Removing/Installing Throttle Cable Fig. 15 Accumulator Springs

TRANSMISSION VALVE BODY INSTALLATION (8) Clean oil screen and oil pan with solvent (if not
(1) Connect cable to throttle cam (Fig. 13). done previously). Dry both components with com
(2) Install check ball and spring (Fig. 16). pressed air only. Do not use shop towels.
(3) Position accumulator springs and spacers on (9) Install new gaskets on oil screen and install
valve body. screen on case. Tighten screen attaching bolts to 10
(4) Align valve body manual valve with shift sec N»m (7 ft. lbs.) torque.
tor (Fig. 17) and carefully position valve body on (10) Apply bead of Mopar or Loctite 599 sealer to
case. sealing surface of oil pan. Sealer bead should be at
(5) Install valve body bolts (Fig. 14). Tighten bolts least 3 mm (1/8 in.) wide. Then install oil pan and
evenly to 10 N*m (7 ft. lbs.) torque. tighten pan bolts to 7.4 N»m (65 in. lbs.) torque.
(6) Install valve body oil tubes. Be sure tube ends (11) Install new gasket on oil pan drain plug and
#
(L) and (M) are installed as shown in Figure 18. install plug in pan. Tighten plug to 20 N m (15 ft.
(7) Remove old sealer material from oil pan and lbs.) torque.
transmission case. (12) Fill transmission with Mopar Mercon™ fluid.
J AW-4 1N-¥EH1CLE SERVICE 21-169
AA
OIL
TUBES
(INSTALL
ill AS SHOWN)
AA
CHECK BALL
AND SPRING J8921-443
J8921-441
Fig. 18 Installing Transmission Valve Body Oil
Fig. 16 Removing/Installing Check Ball And Spring Tubes
AAANUAL MANUAL VALVE SHAFT SEAL REPLACEMENT
VALVE
SHAFT
SEAL PN
AAANUAL
VALVE
SHAFT
SPACER
SLEEVE
SHIFT SHAFT
SECTOR SEAL
SHIFT
SECTOR J8921-442
J8921-444
Fig. 17 Shift Sector And Manual Valve Alignment
Fig. 19 Manual Valve Shaft And Seals
(1) Remove park/neutral position switch and dis
connect transmission shift lever.
(2) Remove oil pan and valve body.
(3) Remove bolts attaching park rod bracket to
case (Fig. 2 0 ) .
(4) Remove park rod from shift sector (Fig. 21).
21 - 170 AW-4 IN-VEHICLE SERVICE
SPACER
AAANUAL
VALVE
J8921-445
Fig. 22 Cutting Spacer Sleeve
Fig. 20 Removing/Installing Park Rod Bracket
VALVE
PARK SHAFT
ROD SEAL
J8921-446
J8921-448
Fig. 21 Removing/Installing Park Rod
Fig. 23 Removing Manual Valve Shaft Seals
(5) Cut spacer sleeve with chisel and remove it
from manual valve shaft (Fig. 22). (13) Lubricate sector and sleeve with petroleum
(6) Remove pin from shaft and sector with pin jelly and install them on shaft.
punch. (14) Align hole in spacer sleeve with notch in sec
(7) Remove shaft and sector from case. tor. Then install shift sector roll pin. Tap pin into
(8) Pry shaft seals out of case (Fig. 23). sector and shaft and stake sleeve to sector and shaft
(9) Inspect the manual valve shaft and sector. Re securely.
place either component if worn or damaged. (15) Connect park rod to sector (Fig. 21).
(10) Coat replacement shaft seals with petroleum (16) Install park rod bracket (Fig. 26). Tighten
jelly and seat them in the case (Fig. 24). bracket bolts to 10 N*m (7 ft. lbs.) torque.
(11) Install new spacer sleeve on sector (Fig. 25). (17) Install valve body, oil screen and oil pan. Use
(12) Lubricate manual valve shaft with petroleum Mopar or Loctite 599 sealer on oil pan seal surface.
jelly and install it in case. (18) Install park/neutral position switch.
J AW-4 IN-VEHICLE SERVICE 21 - 171
PARK
ROD
BRACKET
SHAFT
SEAL
INSTALLER
J8921-449 J8921-451
Fig. 24 Installing Manual Valve Shaft Seals Fig. 26 Installing Park Rod Bracket
pistons one at a time and tag the pistons and

SHIFT
springs for assembly reference. Do not intermix
them.
AIR G U N NOZZLE
IN FEED HOLE
SPACER
SLEEVE
J8921-450 PISTONS
Fig. 25 installing Spacer Sleeve On Sector

ACCUMULATOR PISTONS AND SPRINGS
ACCUMULATOR PISTON AND SPRING J8921-455
REMOVAL
(1) Remove valve body. Refer to procedure in this Fig. 27 Accumulator Piston Removal
section. (3) Remove and discard piston O-ring seals. Then

(2) Remove accumulator pistons with compressed clean pistons and springs with solvent.
air (Fig. 27). Apply air through small feed hole next (4) Inspect pistons, springs and piston bores. Re
to each piston bore. Catch each piston in a shop place worn damaged pistons. Replace broken, col
towel as it exits bore. lapsed or distorted springs. Replace case if piston
bores are damaged.
CAUTION: Use only enough air pressure to ease (5) If small cushion spring in any piston must be
each piston out of the bore. In addition, remove the replaced, remove spring retainer clip and remove
spring from piston (Fig. 28). A small hooked tool or
21-172 AW-4 IN-VEHICLE SERVICE . J
small thin blade screwdriver can be used to remove SECOND COAST BRAKE SERVO
clip. A thin wall, deep socket, or pin punch can be
used to reseat clip after spring replacement. SERVO OVERHAUL
(1) Remove valve body as outlined in this section.
ACCUMULATOR SMALL (2) Remove servo piston cover snap ring with snap
ring pliers (Fig. 30).
RETAINER
CLIP
J9121-414
Fig. 2 8 Small Cushion Spring Retention

(6) Install new O-ring seals on pistons. Lubricate
seals and pistons and piston bores with transmission
fluid.
(7) Install pistons and springs (Fig. 29).
Fig. 30 Removing/Installing Servo Piston Cover

Snap Ring
(3) Remove servo piston and cover with compressed
air. Apply compressed air through oil hole in servo
boss to ease piston out of bore (Fig. 31).
A. O V E R D R I V E CLUTCH ACCUMULATOR P I S T O N A N D S P R I N G S
B. O V E R D R I V E B R A K E ACCUMULATOR P I S T O N A N D S P R I N G S
C. DIRECT CLUTCH ACCUMULATOR P I S T O N A N D S P R I N G S
D. S E C O N D B R A K E ACCUMULATOR P I S T O N A N D S P R I N G S
J9121-378
Fig. 2 9 Accumulator Pistons, Springs And Spacers

(8) Install valve body, oil screen and oil pan. Use
Mopar or Loctite 599 on oil pan sealing surface. Fig. 31 Removing Servo Cover And Piston
(4) Remove and discard seal and O-rings from
J
cover and piston (Fig. 32). Inspect E-ring, piston,
spring and retainer, piston rod and piston spring. Re
place worn or damaged parts.
SERVO PISTON
J8921-451
Fig. 33 Removing/Installing Park Rod Bracket
Fig. 32 Second Coast Brake Servo Components

(5) Install new seals on cover and piston.
(6) Lubricate servo components with transmission
fluid.
(7) Assemble and install servo components in case.
Be sure servo piston rod is properly engaged in the
second coast brake band.
(8) Compress cover and piston and install cover
snap ring.
(9) Install valve body, oil screen and oil pan. Use
Mopar or Loctite 599 on oil pan sealing surface.
PARK ROD AND PAWL SERVICE

PARK ROD AND PAWL REMOVAL
(1) Remove valve body as outlined in this section. PARK
ROD
(2) Remove bolts attaching park rod bracket to J8921-446
case (Fig. 33).
(3) Remove park rod from manual valve shaft sec Fig. 34 Removing/Installing Park Rod
tor (Fig. 34). (2) Disconnect or remove components necessary to
(4) Remove park rod. gain access to seal (e.g. propeller shaft, crossmember,
(5) Remove park pawl, pin and spring (Fig. 35). shift linkage, transfer case, exhaust components,
(6) Examine park rod, pawl, pin and spring. Re hoses, wires).
place any component that is worn or damaged. (3) Remove dust shield and remove seal from
(7) Install pawl in case. Insert pin and install adapter housing (Fig. 36).
spring. Be sure spring is positioned as shown in Fig (4) Install new seal with appropriate size seal in
ure 35. staller and install dust shield.
(8) Install park rod and bracket (Fig. 33). Tighten (5) Reinstall components removed to gain access to
bracket bolts to 10 Nrni (7 ft. lbs.) torque. seal.
(9) Install valve body, oil screen and oil pan as (6) Top off transmission fluid if necessary.
outlined in this section.
ADAPTER HOUSING SEAL REPLACEMENT

(1) Raise vehicle.
21 - 174 AW-4 IN-VEHICLE SERVICE 4
moves past the sensor (Fig. 37). Replace the sensor if

the ohmmeter does not display any kind of reading.
If a digital ohmmeter is being used, the sensor
should generate an ohmmeter readout each time the
switch opens and closes.
CONNECTOR
Fig. 35 Removing/Installing Park Pawl, Pin And

Spring
OIL 2WD ROTOR
4WD TUBE EXTENSION HOUSING J8921-462
ADAPTOR
HOUSING Fig. 37 Speed Sensor Testing
SPEED SENSOR REPLACEMENT
(1) Disconnect sensor wire harness connector.
(2) Remove sensor retainer bolt and remove sensor
(Fig. 38).
RETAINER SPEED
BOLT SENSOR
SPEED
SPEED SENSOR
SENSOR
J9121-379
Fig. 36 Adapter Housing Seals

SPEED SENSOR
SPEED SENSOR TESTING
Test the speed sensor with an ohmmeter. Place the
ohmmeter leads on the terminals in the sensor con
nector (Fig. 37). J8921-463
Rotate the transmission output shaft and observe Fig. 38 Transmission Speed Sensor Removal/
the ohmmeter needle. The needle should deflect indi Installation
cating the switch is opening/closing as the rotor
(3) Remove and discard speed sensor O-ring.
j AW-4 IN-VEHICLE SERVICE 21-175
(4) Install new O-ring on speed sensor and install

sensor in transmission case.
(5) Install sensor bracket and retainer bolt.
Tighten bolt to 7.4 N*m (65 in. lbs.) torque.
(6) Connect sensor wire harness connector.
SPEED SENSOR ROTOR-SPEEDOMETER DRIVE

GEAR
ROTOR-DRIVE GEAR REMOVAL
(1) Raise vehicle.
(2) Remove components necessary to gain access to
rotor and drive gear such as propeller shaft, transfer
case, crossmember, and shift linkage.
(3) Disconnect speedometer cable and/or speed sen
sor.
(4) Remove adaptor housing.
(5) Remove speedometer drive gear snap ring (Fig.
39).
ROTOR
Fig. 40 Removing Speed Sensor Rotor

(3) Tighten adaptor housing bolts to 34 Nmi (25 ft.
lbs.) torque.
(4) Install components removed to gain access to
rotor and drive gear.
THROTTLE POSITION SENSOR (TPS) SERVICE

A separate throttle position sensor is used for au
tomatic transmission applications. The sensor is at
tached to the base of the throttle body. Refer to
Group 14 for TPS service and adjustment.
TRANSMISSION THROTTLE CABLE REPLACEMENT

THROTTLE CABLE REMOVAL
(1) In engine compartment, disconnect cable from
J8921-464
throttle linkage. Then compress cable mounting ears
and remove cable from engine bracket (Fig. 41).
Fig. 39 Removing/Installation Speedometer Drive (2) Raise vehicle.
Gear (3) Remove transmission oil pan.
(6) Remove the speedometer drive gear and spacer (4) Disengage cable from throttle valve cam (Fig.
(if equipped). 42).
(7) Remove rotor by carefully prying it off output (5) Remove cable bracket bolt and remove cable
shaft with wood dowel or hammer handle (Fig. 40). and bracket from case (Fig. 43).
(8) Clean sealing surfaces of transmission case and (6) Remove and discard cable seal.
extension/adaptor housing.
THROTTLE CABLE INSTALLATION
ROTOR AND DRIVE GEAR INSTALLATION (1) Lubricate and install new seal on cable.
(1) Install rotor, spacer (if equipped) and drive (2) Insert cable in transmission case.
gear on output shaft. Then install drive gear snap (3) Attach cable to throttle cam (Fig. 42).
ring (Fig. 39). (4) Install cable bracket on case and tighten at
(2) Apply bead of Mopar or Loctite 599 sealer, to taching bolt to 10 N*m (7 ft-lbs) torque (Fig. 43).
transmission case sealing surface and install exten (5) Remove old sealer material from oil pan and
sion/adapter housing on case. transmission case. Clean oil pan with solvent and
dry it with compressed air.
21 - 171 AW-4 IN-VEHICLE SERVICE
J
CABLE ACCELERATOR
GUIDE CABLE
CONVERTER
THROTTLE HOUSING
CABLE
CABLE
RETAINER
SCREW
CABLE
BRACKET J9321-84
Fig. 41 Transmission Throttle Cable Attachment

THROTTLE
CABLE
CABLE
BRACKET
THROTTLE THROTTLE
CABLE CAM
J8921-438
Fig. 42 Removing/Installing Transmission Throttle

Cable
(6) Apply bead of Mopar or Loctite 599 sealer to oil J8921-452
pan sealing surface. Sealer bead should be at least 3 Fig. 43 Removing/Installing Transmission Throttle
mm (1/8 in.) wide. Then install pan and tighten pan Cable And Bracket
bolts to 7 N»m (65 in. lbs.) torque.
(7) Install new gasket on oil pan drain plug. In (2) Press cable release button (Fig. 44).
stall and tighten plug to 20 N»m (15 ft. lbs.) torque. (3) Push cable conduit back into cable sheath as
(8) Connect cable to engine bracket and throttle far as possible (Fig. 45).
linkage. (4) Rotate lever on throttle body to wide open
(9) F i l l transmission with Mopar Mercon. throttle position. Cable will ratchet to correct adjust
(10) Adjust the cable as described in cable adjust ment point as lever is rotated (Fig. 45).
ment procedure.
SHIFT CABLE ADJUSTMENT
TRANSMISSION THROTTLE CABLE ADJUSTMENT (1) Shift transmission into Park.
(1) Shift transmission into Park, shut engine off (2) Raise vehicle.
and raise hood.
CONDUIT RELEASE (3) Release cable adjuster clamp to unlock cable

BUTTON (Figs. 46 and 47). Clamp is at transmission end of ca
ble.
(4) Unsnap cable from transmission cable bracket
(Figs. 46 and 47).
(5) Move transmission shift lever fully rearward to
CABLE Park detent. Lever is on manual valve shaft at
driver side of case.
(6) Verify positive engagement of park lock by at
tempting to rotate propeller shaft. Shaft will not ro
tate when park lock is engaged.
(7) Snap cable into cable bracket.
CABLE (8) Lock shift cable by pressing cable adjuster
CONNECTOR clamp down until it snaps into place.
J9121-417
(9) Check engine starting. Engine should start
Fig. 44 Throttle Cable Components only in Park and Neutral.
(10) Lower vehicle.
'RELEASE BUTTON
PARK INTERLOCK CABLE ADJUSTMENT
(1) Shift transmission into Park.
(2) T u r n ignition switch to Lock position.
(3) Remove shift lever bezel and console screws.
Raise bezel and console for access to cable.
(4) Pull cable lock button up to release cable (Fig.
47).
(5) Pull cable forward. Then release cable and
press cable lock button down until it snaps in place.
(6) Check adjustment as follows:
(a) Check movement of release shift handle but
ton (floor shift) or release lever (column shift). You
CABLE should not be able to press button inward or move
" BRACKET ^ / \ CABLE MUM J9121-418 column lever.
Fig. 45 Throttle Cable Adjustment (b) T u r n ignition switch to On position.
PARK SHIFT TORQUE

INTERLOCK HANDLE
SHIFT LEVER A 25-39 N * m (221-345 IN. LBS.)
CABLE
A N D HOUSING B 16-26 N » m (141-230 IN. LBS.)
ASSEMBLY
C 1-2 N * m (9-20 IN. LBS.)
SHIFT D 15-17 N « m (134-154 IN. LBS.)
CABLE
MOUNTING
COVER
FLOOR P A N
SHIFT
CABLE
TRANSMISSION
SHIFT LEVER
J9321-86
Fig. 46 Shift Cable

21 - 178 AW-4 IN-VEHICLE SERVICE il
(c) Press floor shift lever release button or move transmission after repair. The flushing procedure ap
column lever. Then shift into Neutral. If cable ad plies to standard (in-radiator) coolers and auxiliary
justment is correct, ignition switch can not be coolers equally.
turned to Lock position. Perform same check with Pressure equipment is preferred for reverse flush
transmission in D range. ing. However, reverse flushing can be performed us
(7) Move shift lever back to Park and check igni ing hand operated equipment as described in the
tion switch operation. You should be able to turn following procedure.
switch to Lock position and shift lever release but (1) Disconnect cooler lines at transmission and at
ton/lever should not move. auxiliary cooler. Refer to Figure 48 for cooler line
identification.
CABLE (2) Position drain pan under cooler line to catch
material flushed through coolers and lines.
(3) Reverse flush each cooler using hand operated
suction gun filled with mineral spirits. Insert gun
nozzle (or hose) into cooler inlet (return) line. Then
force mineral spirits through into line and through
cooler.
(4) Continue reverse flushing until fluid exiting in
let (pressure) line is clear and free of debris/residue.
(5) Replace radiator if fluid cannot be pumped
through main cooler. Replace auxiliary cooler if leaks
are evident, or if fluid cannot be pumped through it.
(6) Clear flushing materials from coolers and lines
with short pulses of compressed air. Insert air gun
J9321-250
nozzle into cooler inlet (return) line and continue
Fig. 47 Park Lock Cable Attachment—XJ short pulses of air until all fluid is cleared from
cooler and lines.
TRANSMISSION COOLER SERVICE (7) Pump one quart of fresh automatic transmis
sion fluid through cooler and lines before reconnect
Main Cooler ing cooler lines.
The transmission main cooler is located in the ra
diator. The main cooler can be flushed when neces FLOW TESTING TRANSMISSION MAIN
sary, however, the cooler is not a repairable COOLER
component. If the cooler is damaged, plugged, or Cooler flow is checked by measuring the amount of
leaking, the radiator will have to be replaced. fluid flow through the cooler in a 20 second time pe
riod. The test is performed with the engine running
Auxiliary Cooler and transmission in neutral. Fluid is then pumped
The auxiliary cooler is mounted in front of the ra through the cooler by the transmission oil pump.
diator at the driver side of the vehicle (Fig. 48). The (1) Disconnect cooler inlet line at transmission fit
cooler can be flushed when necessary, while mounted ting.
in the vehicle. The cooler can also be removed for ac (2) Securely attach hose to end of inlet line and po
cess, repair, or replacement as needed. sition line in a one quart test container.
The main and auxiliary coolers should both be (3) Add extra quart of fluid to transmission.
flushed whenever a transmission or converter clutch (4) Use stopwatch to check flow test time.
malfunction generates sludge, debris, or particles of (5) Shift transmission into neutral and set parking
clutch friction material. brake.
(6) Start and run engine at curb idle speed and im
Cooler Service mediately note cooler flow. Approximately one quart
The main cooler (and radiator) and the auxiliary of fluid should flow into test container in 20 second
cooler can be removed for service or access to other period.
components. Auxiliary cooler removal requires that (7) If cooler flow is intermittent, flows less than
the front bumper and radiator support be removed one quart in 20 seconds, or does not flow at all,
for access to the cooler lines and attaching bracket. cooler is faulty and must be replaced.
REVERSE FLUSHING MAIN AND AUXILIARY

COOLERS AND COOLER LINES
Reverse flushing the cooler and lines will prevent
sludge and particles from flowing back into the
j AW-4 IN-VEHICLE SERVICE 21-179
Fig. 48 Transmission Auxiliary Cooler Mounting

TRANSMISSION COOLER LINE FITTINGS
Quick disconnect fittings are used at the transmis
sion cooler line connections. The fitting seals and
guides are serviceable.
Replace the seals and guides whenever the fittings
exhibit leakage, or will not properly snap into place.
21-180 AW-4 TRANSMISSION REMOVAL AND INSTALLATION
J
AW-4 TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
Oil Pump Seal Replacement 180 Transmission and Torque Converter Installation . 181
Torque Converter Stator Clutch Inspection 180 Transmission and Torque Converter Removal . 180
TRANSMISSION AND TORQUE CONVERTER (13) Remove transfer case from transmission.
REMOVAL (14) Disconnect and remove crankshaft position
(1) Raise vehicle. sensor.
(2) Drain transmission fluid and reinstall oil pan
drain plug. CAUTION: T h e crankshaft position sensor can be
(3) Remove upper half of transmission fill tube damaged if the sensor i s still in place when the
transmission i s removed. T o avoid damage, remove
(Fig. 49).
the sensor before transmission removal.
(15) Remove starter motor.

(16) Remove bolts attaching converter to drive
plate.
UPPER HALF
(17) Remove bolts attaching converter housing to
engine.
(18) Secure transmission to jack with safety
chains.
(19) Pull transmission rearward for access to con
verter. Then secure converter in pump with C-clamp
or strap bolted to converter housing.
(20) Remove transmission from under vehicle.
(21) Remove torque converter if converter or oil
pump seal are to be serviced.
TORQUE CONVERTER STATOR CLUTCH

INSPECTION
(1) Insert Rotating Tool 7547 into converter hub
and seat tool in one-way clutch (Fig. 50).
(2) Insert Stopper Tool 7548 in one converter hub
notch and into outer race of rotating tool.
(3) Turn rotating tool clockwise. Converter clutch
Fig. 49 Two-Piece Transmission Fill Tube should rotate freely and smoothly. Less than 2.5 N*m
(22 in. lbs.) of torque should be required to rotate
(4) Disconnect cooler lines at transmission. Cooler clutch in clockwise direction.
lines have quick-disconnect fittings. Press fitting re (4) Turn rotating tool in counterclockwise direc
lease tabs and pull cooler lines and fittings out of tion. Converter clutch should lock.
case or use Special Tool 7555 to disconnect them. (5) Replace converter if clutch binds or will not
(5) Support engine with safety stand and support lock.
transmission with jack.
(6) Disconnect transmission and transfer case shift OIL PUMP SEAL REPLACEMENT
linkage. (1) Remove converter.
(7) Remove necessary exhaust components. (2) Remove old seal. Use blunt punch to collapse
(8) Disconnect speed sensor wires seal and pry seal out of pump housing. Do not
(9) Mark position of front and rear propeller shafts scratch or damage seal bore.
for alignment reference. Then remove shafts from ve (3) Lubricate lip of new seal with Mopar Mercon
hicle. transmission fluid and install seal in pump with tool
(10) Remove rear crossmember. 7549 (Fig. 51).
(11) Disconnect transmission throttle cable at en (4) Lubricate converter drive hub with Mopar Mer
gine. con transmission fluid.
(12) Disconnect necessary vacuum and fluid hoses. (5) Align and install converter in oil pump.
J AW-4 TRANSMISSION REMOVAL AND INSTALLATION 21 - 181
Fig. 51 Installing Oil Pump Seal

TRANSMISSION AND TORQUE CONVERTER
INSTALLATION
(1) Mount transmission on transmission jack. Then
secure transmission to jack with safety chains.
(2) Lubricate converter drive hub and oil pump
seal lip with Mopar Mercon transmission fluid. Then
install converter. Be sure converter is fully seated in
oil pump gears before proceeding. Hold converter in
place with C-clamp or strap attached to converter
housing.
ROTATING (3) Align and position transmission and converter
TOOL ( T U R N BOTH DIRECTIONS) on engine.
(4) Remove clamp or strap used to hold torque con
verter in place.
(5) Move transmission forward seat and it on en
gine. Be sure torque converter hub is fully seated.
(6) Install converter housing-to-engine bolts (Fig.
52).
(7) Install converter-to-drive plate bolts.
(8) Install and connect starter motor.
(9) Install and connect crankshaft position sensor.
(10) Install transfer case on transmission. Tighten
transfer case attaching nuts to 41 N»m (30 ft. lbs.)
torque
(11) Connect transfer case shift linkage and vac
uum hoses.
(12) Connect exhaust components.
(13) Install rear crossmember and remove jack
J8921-470 used to support transmission assembly.
(14) Connect speed sensor wire harness to sensor.
Fig. 50 Checking Operation Of Torque Converter
(15) Connect wire harness to park/neutral position
Stator One-Way Clutch
switch.
(16) Align and connect front and rear propeller
shafts.
21 - 182 AW-4 TRANSMISSION REMOVAL AND INSTALLATION J
BOLT SET-TO SERVICE T O R Q U E
A 58 N.m (43 ft-lbs)

B 2 0 N.m (181 in-lbs)
TRANSMISSION
FILL
TUBE
FILL
TUBE BRACKET
O-RING BRACKET J9121-397
Fig. 52 AW-4 Transmission Attachment

(17) Connect transmission wire harnesses and (20) Install new O-ring seal on upper half of trans
transfer case vacuum and wire harnesses. mission fill tube. Then connect upper and lower tube
(18) Connect transmission cooler lines. halves.
(19) Connect transmission throttle cable at engine (21) Lower vehicle.
(22) Fill transmission with Mopar Mercon auto
matic transmission fluid. Mopar Dexron II can be
used if Mercon is not readily available.
J AW-4 TRANSMISSION OVERHAUL 21 - 183
AW-4 TRANSMISSION OVERHAUL
INDEX
page page
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 195 Overdrive Support Overhaul . . . . . . . . . . . . . . . . 207
Direct Clutch Overhaul 210 Overhaul Service Tools . . . . . . . . . . . . . . . . . . . 183
First-Reverse Brake Piston and Transmission Rear Planetary, No. 2 One-Way Clutch and
Case Overhaul 229 Output Shaft Overhaul 225
Forward Clutch Overhaul 214 Second Brake Overhaul . . . . . . . . . . . . . . . . . . . 223
Front Planetary Gear Overhaul . . . . . . . . . . . . . 219 Sun Gear and No. 1 One-Way Clutch Overhaul . 220
Manual Valve Shaft Overhaul ........ . . 196 Transmission Assembly and Adjustment . . . . . . 247
Oil Pump Overhaul . . . . . . . . . . . . . . . . . . . . . . 197 Transmission Disassembly . . . . . . . . . . . . . . . . . 183
Overdrive Planetary Gear and Clutch Overhaul . 200 Transmission Valve Body Overhaul . . . . . . . . . . 232
OVERHAUL SERVICE TOOLS (4) Remove shift lever from manual valve shaft at
The special tools needed to overhaul the AW-4 left side of transmission.
transmission are provided in Tool Kit 6294. How (5) Remove park/neutral position switch.
ever, Pressure Test Port Adapter 7554 is not in (6) Remove speed sensor (Fig. 2).
cluded in this kit and must be ordered separately.
The overhaul tool kit and test port adapter are avail
able through the parts division and dealer special
tool program.
TRANSMISSION DISASSEMBLY
(1) Remove torque converter.
(2) Remove lower half of filler tube if not previ
ously removed.
(3) Remove clamps attaching wire harness and
throttle cable (Fig. 1) to transmission.
CLAMP
SPEEDOMETER
DRIVEN GEAR (2WD MODELS)
SPEED
SENSOR
J8921-475
Fig. 2 Speed Sensor Removal

TRANSMISSION THROTTLE
HARNESS CABLE
J8921-474
Fig. 1 Typical Harness And Cable Clamp

Attachment
21-184 AW-4 TRANSMISSION OVERHAUL J
(7) Remove converter housing bolts and remove (10) Remove speed sensor rotor and key. Use wood
housing (Fig. 3) from case. dowel or hammer handle to loosen and remove rotor
(Fig. 5).
CONVERTER HOUSING
J8921-476
Fig. 3 Removing/Installing Converter Housing

(8) Remove adapter housing.
( 9 ) Remove speedometer drive gear snap ring and Fig. 5 Removing Transmission Speed Sensor Rotor
remove gear and gear spacer i f equipped (Fig. 4 ) .
(11) Remove transmission oil pan, oil screen and
ROTOR screen gaskets (Fig. 6). Then mount transmission in
holding fixture.
Fig. 6 Removing Oil Screen

J8921-464
Fig. 4 Removing Speed Sensor And Speedometer

Drive Gear
J .—, . — AW-4 TRANSMISSION OVERHAUL 21 - 185
(12) Remove valve body oil feed tubes (Fig. 7). (14) Remove harness bracket bolt and remove har
ness and bracket Fig. 9).
J8921-436
J8921-437
Fig. 7 Removing Valve Body Oil Tubes Fig. 9 Removing Bracket And Harness
(13) Disconnect valve body solenoid wires (Fig. 8 ) . (15) Remove valve body bolts (Fig. 10).
SOLENOID W I R E • = B O L T LOCATIONS
CONNECTORS
o o o o o. o
J8921-439
J8921-433
Fig. 10 Valve Body Bolt Locations
Fig. 8 Solenoid Wire Location
21-186 AW-4 TRANSMISSION OVERHAUL
(16) Disconnect throttle cable from throttle cam SECOND BRAKE A N D

(Fig. 11). CLUTCH PISTONS
OVERDRIVE
BRAKE
THROTTLE
Fig. 11 Disconnecting Throttle Cable

(17) Remove valve body from case. Then remove
accumulator springs, spacers and check ball and
spring (Fig. 12).
ACCUMULATOR SPRINGS
J9121-381
Fig. 12 Removing Accumulator Springs, Spacers

And Check Ball
(18) Remove second brake and clutch accumulator
pistons with compressed air (Fig. 13). Apply air pres
sure through feed port and ease the pistons out of the
bore. J8921-480
(19) Remove overdrive brake accumulator piston
with compressed air (Fig. 13). Fig. 13 Removing Accumulator Pistons
(20) Remove overdrive clutch accumulator piston
with compressed air (Fig. 13).
(21) Remove throttle cable.
AW-4 TRANSMISSION OVERHAUL 21-187
J (22) Remove oil pump bolts and remove pump with F O U R T H GEAR
bridge-type Puller 7536 (Fig. 14).
PULLER
J8921-483
PUMP J8921-481
Fig. 16 Removing Fourth Gear Planetary And Direct
Fig. 14 Oil Pump Removal Clutch Assembly
(23) Remove race from oil pump (Fig. 15).
F O U R T H GEAR
PLANETARY
(OVERDRIVE)
RACE
J8921-482 J8921-484
Fig. 15 Oil Pump Race Removal Fig. 17 Fourth Gear Planetary Race Removal
(24) Remove fourth gear overdrive planetary gear (26) Remove thrust bearing, race and overdrive
and overdrive direct clutch assembly (Fig. 16). planetary ring gear (Fig. 18).
(25) Remove race from fourth gear overdrive plan (27) Measure stroke length of overdrive brake pis
etary (Fig. 17). ton as follows:
(a) Mount dial indicator on case (Fig. 19).
(b) Mount Gauge Tool 7546 so it contacts piston
(Fig. 19).
(c) Apply 57-114 psi air pressure through piston
apply port and note piston stroke on dial indicator.
Stroke length should be: 1.40 - 1.70 mm (0.055 -
0.0699 in.).
21 - 188 AW-4 TRANSMISSION OVERHAUL J
J8921-485
Fig. 18 Removing Rearing, Race And Planetary Ring J8921-487

Gear Fig. 20 Removing Overdrive Brake Snap Ring
(29) Remove overdrive brake discs and plates (Fig.
2l). Then measure disc thickness with a micrometer.
Minimum disc thickness is 1.84 mm (0.0724 in.). Re
place discs if thickness is less than specified.
Fig. 19 Measuring Overdrive Brake Piston Stroke

(d) If stroke is not within limits, replace brake
1.84AAM ( . 0 7 2 I N )
pack retainer. Select required retainer from Over
drive Brake Retainer Selection chart in Specifica
tions section. J8921-4S8
(28) Remove overdrive brake snap ring (Fig. 20). Fig. 21 Removing/Measuring Overdrive Brake Disc
Thickness
(30) Remove overdrive support lower race and up (32) Remove overdrive support snap ring with
per bearing and race assembly (Fig. 22). Snap Ring Plier Tool 7540 (Fig. 24).
UPPER BEARING A N D RACE S N A P RING
PLIERS
LOWER RACE
SUPPORT
SNAP
RING
J8921-489
J8921-49J
Fig. 22 Overdrive Support Bearing/Race Removal
Fig. 24 Removing/Installing Overdrive Support Snap
(31) Remove overdrive support bolts (Fig. 23). Ring
(33) Remove overdrive support (Fig. 25) with
bridge-type Puller 7536.
BRIDGE-TYPE
PULLER TOOL
•SUPPORT
BOLTS
J8921-490
Fig. 23 Overdrive Support Bolt Removal OVERDRIVE

SUPPORT
J8921-492
Fig. 25 Removing Overdrive Support

(34) Remove race from hub of overdrive support (b) Apply 57-114 psi air pressure through piston
J
(Fig. 26). feed hole and check stroke length with Gauge Tool
7552 (Fig. 27).
(c) Stroke length should be 1.5 - 3.0 mm (0.059 -
0.118 in.).
(d) If stroke length is incorrect, install new pis
ton rod and recheck stroke. If stroke is still incor
rect, replace second coast brake band.
(e) Replacement piston rods are available in two
different lengths which are: 71.4 mm (2.811 in.)
and 72.9 mm (2.870 in.).
(36) Remove second coast brake piston snap ring
with Snap Ring Plier Tool 7540. Then remove piston
cover and piston assembly with compressed air ap
plied through piston feed hole (Fig. 28).
J8921-493
Fig. 26 Remove Overdrive Support Race

(35) Measure stroke length of second coast brake
piston rod as follows:
(a) Make reference mark on piston rod (Fig. 27)
as shown. S N A P RING, PISTON
A N D COVER
(AAAKE W I T H
GREASE PENCIL)
Fig. 28 Removing Second Coast Brake Cover And

Piston
J8921-494
Fig. 27 Measuring Second Coast Brake Piston Rod

Stroke
ll AW-4 TRANSMISSION OVERHAUL 21 - 191
(37) Disassemble second coast brake piston (Fig. DIRECT

29). CLUTCH
SERVO PISTON
J8921-497
Fig. 31 Remove Bearing And Race From Clutch Hub
Fig. 29 Second Coast Brake Piston Components

(38) Remove direct and forward clutch assembly
(Fig. 30).
DIRECT A N D
FORWARD
BRAKE BAND
E-RING
J8921-496
Fig. 30 Removing Direct And Forward Clutch

Assembly
(39) Remove thrust bearing and race from clutch Fig. 32 Removing Second Coast Brake Band
hub (Fig. 31). (42) Remove thrust bearing and rear race from
(40) Remove second coast brake band E-ring from ring gear (Fig. 34).
band pin and remove brake band (Fig. 32). (43) Remove planetary thrust race (Fig. 35).
(41) Remove front planetary ring gear front bear (44) Relieve load on planetary snap ring as follows:
ing race and remove front planetary ring gear (Fig. Loosen transmission holding fixture. Turn transmis-
33).
RING GEAR BEARING THRUST

J?ACE (FRONT) RACE
FRONT PLANETARY RING GEAR
J8921-499 J8921-501
Fig. 33 Removing Front Planetary Ring Gear Fig. 35 Relieving Load On Planetary Snap Ring
FRONT
BEARING PLANETARY
A N D REAR RING GEAR
RACE
PLANETARY
S N A P RING
SNAP RING
PLANETARY PLIERS
GEAR
J8921-500
Fig. 34 Removing Ring Gear Bearing And Rear Race

sion over and allow output shaft to support transmis
sion weight. Place wood blocks under shaft to protect
splines (Fig. 35).
(45) Remove planetary snap ring and remove plan J8921-502
etary gear (Fig. 36).
(46) Remove sun gear, input drum and one-way Fig. 36 Removing Planetary Snap Ring And Gear
AW-4 TRANSMISSION OVERHAUL 21-193
J
clutch as assembly (Fig. 3 7 ) .
CLUTCH PACK
S N A P RING
J8921-505
Fig. 39 Removing Second Brake Clutch Pack Snap

Ring
J8921-503 thickness should be 1.84 mm (0.0724 in.). Replace
discs if not within specifications.
Fig. 37 Removing Sun Gear, Input Drum And
One-Way Clutch
(47) Measure second brake clutch pack clearance
(Fig. 38). Clearance should be 0.62 - 1.98 mm (0.0244 SECOND
- 0.0780 in.). Replace discs if clearance is not within BRAKE
CLUTCH
specifications. PACK
FEELER
GAUGE
SECOND
BRAKE
CLUTCH
M I N . DISC THICKNESS
IS 1.84MM (.072 IN)
J8921-506
Fig. 38 Checking Second Brake Clutch Pack
Clearance Fig. 40 Remove/Measure Second Brake Clutch Disc
(48) Remove second brake clutch pack snap ring Thickness
(Fig. 39). (50) Remove bolts attaching park rod bracket to
(49) Remove second brake clutch pack (Fig. 40). case. Then disconnect park rod from manual shaft le
Measure disc thickness with micrometer. Minimum ver and remove rod and bracket (Fig. 41).
(52) Measure clearance of first-reverse brake

clutch pack (Fig. 43). Clearance should be: 0.70 - 1.2
mm (0.028 - 0.047 in.). Replace discs if clearance is
not as specified.
FIRST-REVERSE
CLUTCH PACK
J8921-508
Fig. 43 Checking First-Reverse Brake Clutch Pack

Clearance
(53) Remove second brake piston sleeve (Fig. 44).
Cover remover tool with tape to avoid damaging
case.
REMOVER
J8921-509
Fig. 44 Removing Second Brake Piston Sleeve

(54) Remove rear planetary gear, second brake
Fig. 42 Removing Park Pawl, Pin And Spring drum and output shaft as an assembly (Fig. 45).
(55) Remove planetary and brake drum thrust
bearing and race assembly (Fig. 46).
SECOND
BRAKE
DRUM
J8921-753
Fig. 47 Removing Brake Drum Gasket

Fig. 45 Removing Rear Planetary, Second Brake
Drum And Output Shaft
THRUST
J8921-511 Fig. 48 Checking Rear Bushing Inside Diameter
Fig. 46 Removing Planetary And Brake Drum Thrust

Bearing And Race Assembly Clean the transmission components with solvent
and dry them with compressed air only. Do not use
(56) Remove second brake dram gasket from case shop towels or rags.
with gasket scraper or screwdriver (Fig. 47). Retain Blow compressed air through all oil feed passages
tube shaped gasket if condition is OK. and channels to be sure they are clear. Inspect the
(57) Measure inside diameter of transmission case transmission components for wear and damage. Re
rear bushing with bore gauge or inside micrometer place components that are damaged or worn beyond
(Fig. 48). Maximum allowable diameter is 38.18 mm the limits specified in the individual overhaul proce
(1.5031 in.). Replace transmission case if bushing dures.
I.D. is greater than specified. Bushing is not ser Replace all O-rings, gaskets and seals. These com
viceable. ponents are not reusable. Also replace any snap ring
that is distorted or damaged.
During overhaul assembly operations, lubricate the SPACER

transmission components with Jeep or Mopar Mer
con™ automatic transmission fluid or petroleum jelly
as indicated. Petroleum jelly should be used to prelu-
bricate thrust bearings, washers and races. It can
also be used to hold parts in position during assem
bly.
Soak replacement clutch and brake pack com
ponents i n transmission fluid for at least 30 min
utes before installation.
MANUAL VALVE SHAFT OVERHAUL

SHAFT
SEAL PN
AAANUAL
MANUAL
VALVE
VALVE
SHAFT
SHAFT
JS921-447
Fig. 2 Cutting Shaft Spacer Sleeve

PIN
PUNCH
MANUAL
SPACER SHAFT
SLEEVE
SHIFT SHAFT
SECTOR SEAL
J8921-444
Fig. 1 Manual Valve Shaft Components

(1) Cut shaft spacer sleeve in half with chisel and
remove it from lever and shaft (Fig. 2).
(2) Remove shift sector retaining pin with pin
punch (Fig. 3).
(3) Pull shaft out of case and remove manual lever. SHIFT
SECTOR
(4) Carefully pry shaft seals from case. J8921-513
(5) Lubricate new seals with petroleum jelly and
install them in case (Fig. 4 ) . Fig. 3 Removing/Installing Sector Retaining Pin
(6) Install new spacer sleeve on shift sector (Fig.
5).
(7) Install sector and sleeve on shaft and install
shaft in case.
(8) Align sector and sleeve and install new retain
ing pin.
(9) Align notch in sleeve with depression in sector
and stake sleeve in two places. Be sure lever and
shaft rotate smoothly.
SEAL INSTALLER SLEEVE

TOOL SECTOR
SECTOR
AND
SLEEVE
J8921-514
Fig. 4 Installing Manual Shaft Seals

SHAFT
OIL PUMP OVERHAUL
(1) Remove pump body O-ring (Fig. 1).
(2) Remove pump seal rings (Fig. 1).
(3) Remove bolts attaching stator shaft to pump
body and separate components. J8921-515
(4) Remove drive gear and driven gear from pump
body (Fig. 1). Fig. 5 Installing Manual Shaft And Sector
(5) Measure inside diameter of pump body bushing
with bore gauge or inside micrometer (Fig. 2). Diam
eter should be maximum of 38.19 mm (1.5035 in.).
Replace pump body if bushing I.D. is greater than
specified.
PUMP
BODY STATOR.
SHAFT SEAL
RINGS
PUMP
SEAL
O-RING
J8921-516
Fig. 1 Oil Pump Components

(6) Measure inside diameter of stator shaft bush

ing (Fig. 2). Take measurements at front and rear of
bushing. Diameter should be maximum of 21.58 mm
(0.08496 in.) at front and 27.08 mm (1.0661 in.) at
rear. Replace stator shaft if bushing diameter is
greater than specified.
BODY-TO-
DRIVEN GEAR CLEARANCE
J8921-517
Fig. 2 Checking Pump/Stator Shaft Bushings

(7) Measure oil pump clearances (Fig. 3).
• Clearance between pump driven gear and pump
body should be maximum of 0.3 mm (0.012 in).
• Clearance between tips of pump gear teeth should
be maximum of 0.3 mm (0.012 in).
• Clearance between rear surface of pump housing
and pump gears should be maximum of 0.1 mm
(0.004 in.).
(8) Replace pump body and gears if any clearance
is greater than specified.
Fig. 3 Checking Pump Gear Clearances

AW-4 TRANSMISSION OVERHAUL 21 - 199
J (9) Remove old pump seal. Install new seal with
OIL
Seal Installer 7549 (Fig. 4). PUMP
J8921-519
Fig. 4 Installing Pump Seal

TORQUE
CONVERTER
(10) Lubricate and install gears in pump body.
J8921-520
(11) Assemble stator shaft and pump body. Tighten
#
shaft-to-body bolts to 10 N m (7 ft. lbs.) torque. Fig. 5 Checking Pump Gear Rotation
(12) Install new O-ring on pump body and new
seal rings on stator shaft.
(13) Install pump in torque converter and check
pump gear rotation. Gears must rotate smoothly
when turned clockwise and counterclockwise.
(14) Lubricate pump O-ring and seal rings with pe
troleum jelly.
21 - 200 AW-4 TRANSMISSION OVERHAUL
CLUTCH
DISCS
CLUTCH PISTON RETAINER PLATE
CLUTCH D R U M
SNAP RING
RETAINING PLATE
PLANETARY
RING GEAR
J8921-521
Fig. 1 Overdrive Planetary Gear And Clutch Components

OVERDRIVE PLANETARY GEAR AND CLUTCH and counterclockwise. Shaft should turn clockwise
OVERHAUL freely but lock when turned counterclockwise. Re
place one-way clutch if necessary.
GEAR AND CLUTCH DISASSEMBLY (2) Remove overdrive clutch from planetary gear
(1) Check operation of one-way clutch in clutch (Fig. 3).
drum. Hold drum and turn planetary shaft clockwise (3) Remove thrust bearing and race assembly from
clutch drum (Fig. 4 ) .
J8921-522
Fig. 2 Checking One-Way Clutch

OVERDRIVE
CLUTCH
GEAR
J8921-523
l W v
TORQUE ~ ^
CONVERTER
Fig. 3 Removing Overdrive Clutch From Gear
J8921-525
(4) Measure stroke length of clutch piston as fol
lows: Fig. 5 Assembling Converter, Pump And Clutch For
(a) Mount oil pump on torque converter. Then Test
mount clutch on oil pump (Fig. 5).
(b) Mount dial indicator on clutch and position
indicator stylus on clutch piston (Fig. 6).
(c) Apply compressed air through clutch feed
hole in oil pump and note piston stroke length.
Stroke length should be 1.85 - 2.15 mm (0.0728 -
0.0846 in.).
(5) Replace clutch pack retainer if stroke length is
incorrect. Refer to chart in Specifications section for
replacement retainer thicknesses.
T H R O U G H FEED H O L E
T O OPERATE CLUTCH P I S T O N
J8921-526
Fig. 6 Checking Overdrive Clutch Piston Stroke

(6) Remove clutch pack snap ring and remove the Fig. 8 Removing Clutch Piston Snap Ring
clutch pack.
(10) Hold clutch piston by hand and apply com
pressed air through oil pump feed hole to ease piston
out (Fig. 9). Apply only enough air pressure to re
move piston.
J8921-527
Fig. 7 Removing Clutch Pack Snap Ring

(7) Compress piston return spring with Tool 7538
(Fig. 8). Remove snap ring and remove compressor
tool. J8921-529
(8) Remove compressor tool and piston return
springs. Fig. 9 Removing Overdrive Clutch Piston
(9) Mount oil pump on converter. Then mount
(11) Remove bearing and race from ring gear (Fig.
clutch on oil pump (Fig. 9).
10).
Fig. 12 Remove Planetary Gear Race

(14) Remove snap ring and remove retaining plate
(Fig. 13).
Fig. 13 Removing Snap Ring And Retaining Plate

(15) Remove one-way clutch and outer race as as
sembly. Then separate race from clutch (Fig. 14).
(16) Remove thrust washer (Fig. 15).
(17) Measure clutch disc thickness. Minimum al
lowable thickness is 1.84 mm (0.0724 in.).
Fig. 11 Removing Ring Gear Hub

(13) Remove race from planetary gear (Fig. 12).
ONE-WAY
CLUTCH
AND
OUTER
RACE
ASSEMBLY
SPRING
RETAINER
J8921-536
Fig. 16 Checking Piston Return Spring Length

ball sealing by applying low pressure compressed air
to ball inlet as shown. Air should not leak past check
ball.
CLUTCH PISTON
J8921-534 CHECK BALL
Fig. 14 Removing One-Way Clutch U S E LOW-PRESSURE

COMPRESSED AIR
(18) Measure free length of piston return springs T O T E S T BALL SEATING
with springs in retainer (Fig. 16). Length should be

16.8 mm (0.661 in.).
(19) Check clutch piston check ball (Fig. 17).
Shake piston to see if ball moves freely. Then check
J8921-537
Fig. 17 Testing Clutch Piston Check Ball

THRUST
WASHER (20) Check inside diameter of clutch drum bush
ings with bore gauge or inside micrometer (Fig. 18).
Maximum inside diameter is 27.11 mm (1.0673 in.).
Replace drum if bushing inside diameter is greater
PLANETARY than specified.
GEAR
(21) Check inside diameter of planetary gear bush
ing (Fig. 19). Maximum inside diameter is 11.27 mm
(0.4437 in.). Replace planetary gear if bushing inside
J8921-535 diameter is greater then specified.
Fig. 15 Removing Planetary Thrust Washer

CLUTCH
DRUM
J8921-538
Fig. 18 Checking Clutch Drum Bushings

PLANETARY Fig. 20 Install Planetary Thrust Washer
BUSHING
J8921-539
J8921-540
Fig. 19 Checking Planetary Bushing
Assembling Gear And Clutch Fig. 21 Assembling One-Way Clutch And Race
(1) Install thrust washer in planetary gear (Fig. (5) Coat planetary race with petroleum jelly and
20). Grooved side of washer faces up and toward install it on planetary gear. Outside diameter of race
front. is 41.8 mm (1.646 in.); inside diameter is 27.1 mm
(2) Install one-way clutch in race (Fig. 21). (1.067 in.).
Flanged side of clutch must face upward as shown. (6) Install hub in planetary ring gear and install
(3) Install assembled one-way clutch and outer snap ring.
race in planetary gear. Be sure flanged side of clutch (7) Coat race and bearing with petroleum jelly and
is facing upward. install in planetary ring gear (Fig. 22).
(4) Install clutch pack retaining plate and snap (8) Verify bearing/race size. Outside diameter of
ring in planetary gear. race is 47.8 mm (1.882 in.) and inside diameter is
24.2 mm (0.953 in.). Outside diameter of bearing is
46.8 mm (1.843 in.) and inside diameter is 26 mm
(1.024 in.).
Fig. 22 Install Ring Gear Bearing And Race

(9) Lubricate and install new O-rings on clutch
piston. Then install piston in clutch drum.
(10) Install piston return springs in clutch piston
(Fig. 23).
CLUTCH STEEL
DRUM PLATE
J8921-543
Fig. 25 Installing Clutch Discs And Plates

(13) Install clutch pack retainer with flat side fac
ing downward. Then install retainer snap ring (Fig.
26). Compress springs with suitable tool.
(14) Measure clutch piston stroke length again (re
fer to procedure outlined in disassembly procedure ) .
Fig. 23 Installing Piston Return Springs If stroke length is incorrect, install new clutch discs
(11) Install piston snap ring. Compress piston re or select fit retainer. Retainer thicknesses are out
turn springs with Tool 7538 and shop press (Fig. 24). lined in the Specifications section.
(12) Install clutch pack in drum. Install steel plate (15) Install clutch drum bearing and race assembly
first, then a disc (Fig. 25). Continue installation se (Fig. 27). Be sure bearing rollers face upward as
quence until required number of discs and plates shown. Outside diameter of assembled bearing and
have been installed. race is 50.2 mm (1.976 in.). Inside diameter is 28.9
mm (1.138 in.).
BEARING
AND
RACE
ASSEMBLY
CLUTCH PACK
RETAINER
CLUTCH
DRUM
J8921-545
Fig. 27 Installing Clutch Drum Bearing And Race

Assembly
OVERDRIVE SUPPORT OVERHAUL
J8921-544 SUPPORT DISASSEMBLY
(1) Check brake piston operation. Mount support
Fig. 26 Installing Retainer And Snap Ring on clutch (Fig. 2).
(16) Install clutch on planetary gear. (2) Apply compressed air through support feed hole
(17) Verify one-way clutch operation. Hold drum and observe brake piston movement (Fig. 2). Piston
and turn planetary shaft clockwise and counterclock should move smoothly and not bind or stick. If oper
wise. Shaft should turn clockwise freely but lock ation is incorrect, replace piston and support.
when turned counterclockwise.
PISTON BRAKE PISTON FRONT REAR OVERDRIVE

S N A P RING RACE RACE SUPPORT
BEARING
RACE
PISTON R E T U R N SPRING
J8921-546
Fig. 1 Overdrive Support Components

BRAKE PISTON
BEARING
RACE
OVERDRIVE
' SUPPORT
THRUST
WASHER
J8921-547
Fig. 2 Checking Brake Piston Movement

(3) Remove thrust bearing front race, thrust bear
ing and rear race (Fig. 3).
J8921-549
F R O N T RACE
Fig. 4 Removing Clutch Drum Thrust Washer And

T H R U S T BEARING Race
REAR RACE
COMPRESSOR
TOOL
J8921-548 J8921-550
Fig. 3 Removing Support Thrust Bearing And Races Fig. 5 Removing/Installing Piston Snap Ring
(4) Turn overdrive support over and remove bear (8) Remove support seal rings (Fig. 6).
ing race and clutch drum thrust washer (Fig. 4). (9) Measure free length of piston return springs
(5) Compress piston return spring with Spring with springs mounted in retainer (Fig. 7). Length
Compressor 7537 and remove piston snap ring (Fig. should be 17.23 mm (0.678 in.).
5). (10) Clean support components and dry them with
(6) Mount support in direct clutch and remove compressed air.
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O-rings (Fig. 1).
SEAL
RINGS (2)
SUPPORT
J8921-551
Fig. 6 Removing Support Seal Rings
Fig. 8 Installing Support Seal Rings

(6) Install thrust bearing and front and rear bear
ing races. Thrust bearing rollers should face upward
as shown (Fig. 9).
(7) Verify thrust bearing/race sizes (Fig. 9).
• Front race outer diameter is 47.8 mm (1.882 in.)
and inside diameter is 30.7 mm (1.209 in.).
• Rear race outer diameter is 47.8 mm (1.882 in.)
• Bearing outer diameter is 47.7 mm (1.878 in.) and
inside diameter is 32.7 mm (1.287 in.).
FRONT
SPRING
RETAINER
J8921-536

(11) Inspect overdrive support and brake piston.
Replace support and piston if either part is worn or
damaged.
ASSEMBLING OVERDRIVE SUPPORT

(1) Lubricate new support seal rings. Then com
press rings and install them on support (Fig. 8).
(2) Lubricate and install new O-rings on brake pis
ton. Then carefully seat piston in support.
(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres
sor 7537 (Fig. 5) and install piston snap ring.
(5) Install support bearing race and clutch drum Fig. 9 Installing Support Thrust Bearing And Races
thrust washer (Fig. 4).
(8) Verify brake piston operation. Use same proce (5) Mount dial indicator on clutch and position in
dure described at beginning of disassembly. Piston dicator plunger on clutch piston (Fig. 4).
should operate smoothly and not bind or stick. (6) Apply 57-114 psi air pressure through feed hole
in overdrive support and note piston stroke length
DIRECT CLUTCH OVERHAUL (Fig. 4). Check stroke at least twice.
(7) Piston stroke length should be 1.37 mm - 1.67
CLUTCH DISASSEMBLY mm (0.054 -0.065 in.). If stroke length is incorrect,
(1) Remove direct clutch from forward clutch (Fig. either the clutch pack retainer or clutch discs will
1). have to be replaced.
DIRECT CLUTCH
DIRECT CLUTCH
FORWARD
CLUTCH
OVERDRIVE
SUPPORT
J8921-555
J8921-557
Fig. 1 Separate Direct Clutch From Forward Clutch
(2) Remove clutch drum thrust washer (Fig. 2).
PISTON
J8921-556 J8921-558
Fig. 2 Removing Clutch Drum Thrust Washer Fig. 4 Checking Direct Clutch Piston Stroke Length
(3) Check clutch piston stroke length as outlined (8) Remove clutch pack snap ring and remove re
in following steps. tainer and clutch pack from drum (Fig. 5).
(4) Mount direct clutch on overdrive support as (9) Compress clutch piston return springs with tool
sembly (Fig. 3). 7538 and remove clutch piston snap ring (Fig. 6).
Fig. 5 Removing Clutch Pack Snap Ring Fig. 7 Removing Direct Clutch Piston
(14) Measure free length of piston return springs
with springs in retainer (Fig. 8). Length should be
21.32 mm (0.839 in.). Replace return springs if not
within specification.
SPRING
Fig. 6 Removing Piston Return Spring RETAINER
J8921-536
(10) Remove compressor tool and return spring.
(11) Remove clutch piston. Remount clutch on
overdrive support (Fig. 7). Apply compressed air
through piston feed hole in support to remove piston. (15) Check clutch piston check ball (Fig. 9). Shake
Use only enough air to ease piston out. piston to see if ball moves freely. Then check ball
(12) Remove and discard clutch piston O-rings. seating by applying low pressure compressed air to
(13) Measure clutch disc thickness. Minimum al ball inlet as shown. Air should not leak past check
lowable thickness is 1.84 mm (0.0724 in). Replace ball.
discs if below minimum thickness. (16) Measure inside diameter of clutch drum bush
ing. Inside diameter should be no more than 53.97
PISTON DIRECT CLUTCH ASSEMBLY

(1) Lubricate and install replacement O-rings on
clutch piston (Fig. 10).
(2) Install clutch piston in drum and install return
springs on piston.
(3) Compress piston return springs with Tool 7538
and install snap ring (Fig. 6). Be sure snap ring end
gap is not aligned with spring retainer tab.
(4) Install clutch discs and plates (Fig. 11). Install
plate then disc until all plates and discs are in
stalled. Four plates and discs are required.
(5) Install clutch pack retainer in drum (Fig. 12).
(6) Install clutch pack snap ring (Fig. 12).
(7) Check snap ring position. If necessary, shift
snap ring until end gap is not aligned with any
notches in clutch drum (Fig. 12).
(8) Check clutch piston stroke length a second
time. If length is OK, continue with assembly. If
J8921-562 stroke length is incorrect, replace clutch discs or use
different thickness clutch pack retainer (Fig. 12). See
Fig. 9 Testing Piston Check Bail Seating Specifications section for retainer thicknesses.
mm (2.1248 in.). Replace drum if bushing inside di (9) Lubricate clutch drum thrust washer with pe
ameter is greater than specified. troleum jelly and install it in drum (Fig. 3).
Fig. 10 Direct Clutch Components

J
CLUTCH CLUTCH PACK S N A P RING
DISCSv
DRUM NOTCH ,
SHIFT S N A P RING E N D GAP

AWAY FROM DRUM NOTCHES
J8921-563
J8921-565
Fig. 11 Installing Direct Clutch Discs And Plates Fig. 13 Adjusting Clutch Pack Snap Ring Position
CLUTCH PACK
'RETAINER
DIRECT
CLUTCH
J8921-564 FORWARD M QC//9 1

CLUTCH J8921-566
Fig. 12 Install Clutch Pack Retainer Fig. 14 Checking Direct Clutch Assembled Height
(10) Mount direct clutch assembly on forward
clutch assembly and check assembled height (Fig.
14). Height should be 70.3 to 71.5 mm (2.767 to 2.815
in.).
(11) If assembled height is incorrect, clutches are
not seated.
(12) If clutch height is OK, remove direct clutch
from forward clutch and proceed to forward clutch
overhaul.
J8921-567
Fig. 1 Forward Clutch Components

FORWARD CLUTCH OVERHAUL (4) Mount dial indicator on clutch drum. Position
dial indicator plunger against clutch piston (Fig. 3 ) .
FORWARD CLUTCH DISASSEMBLY (FIG. 1) (5) Apply compressed air through right side feed
(1) Check clutch piston stroke as outlined in fol hole in support and note piston stroke length on dial
lowing steps. indicator.
(2) Position overdrive support on wood blocks and (6) Stroke length should be 3 . 5 5 - 3 . 7 3 mm ( 0 . 1 3 4 8
mount forward clutch drum on support (Fig. 2). - 0.1469 in.).
(3) Remove bearing and race from forward clutch (7) Replace clutch discs if stroke length is incor
drum (Fig. 2). rect.
4 AW-4 TRANSMISSION OVERHAUL 21 - 215
F i g . 2 Positioning Drum And Support On Wood

Blocks
DIAL
J8921-571
PISTON F i g . 5 Removing Cushion Plate

J8921-569
(13) Apply compressed air through feed hole in
F i g . 3 Checking Forward Clutch Piston Stroke support to remove piston (Fig. 6). Use only enough
Length air pressure to ease piston out of drum.
(14) Remove and discard clutch piston O-rings.
(8) Remove clutch pack snap ring and remove re (15) Remove clutch drum O-ring from rear hub of
tainer and clutch pack (Fig. 4). drum.
(9) Remove clutch pack cushion plate (Fig. 5).
(10) Compress clutch springs with Tool 7538 and
remove piston snap ring.
(11) Remove spring compressor tool and piston re
turn springs.
(12) Remount forward clutch drum on overdrive
support (Fig. 6).
CLUTCH SEAL
PISTON RINGS
OVERDRIVE
SUPPORT
CLUTCH
DRUM
J8921-574
J8921-572
Fig. 8 Removing Clutch Drum Seal Rings
Fig. 6 Removing Forward Clutch Piston
CLUTCH
DRUM
HUB
THRUST
BEARING
AND
RACE
ASSEMBLY
O-RING
J8921-575
J8921-573
Fig. 9 Removing Clutch Drum Thrust Bearing

Fig. 7 Removing/Installing Clutch Drum O-Ring
Assembly
(16) Remove three seal rings from clutch drum (19) Measure free length of piston return springs
shaft (Fig. 8). with springs mounted in retainer (Fig. 11). Length
(17) Remove thrust bearing and race assembly should be 19.47 mm (0.767 in.). Replace springs and
from clutch drum (Fig. 9). retainer if length is incorrect.
(18) Measure clutch disc thickness (Fig. 10). Mini
mum allowable thickness is 1.51 mm (0.0595 in.).
PISTON
CHECK BALL
CLUTCH
DISC
USE L O W
AIR PRESSURE
FOR T E S T
J8921-577
J8921-576
Fig. 12 Testing Piston Check Ball
Fig. 10 Measuring Clutch Disc Thickness Race side of assembly faces downward and toward
drum. Bearing rollers face up (Fig. 13)
THRUST
BEARING
K A N D RACE
BEARING
ROLLERS
FACE U P
FORWARD
CLUTCH
SPRING
RETAINER
J8921-536
Fig. 11 Checking Return Spring Length

(20) Inspect clutch piston check ball (Fig. 12). Ball J8921-578
should move freely within piston. Check ball seating

by applying low pressure compressed air to ball feed Fig. 13 Installing Thrust Bearing And Race
hole. Ball should seat firmly and not leak air. (2) Coat new clutch drum shaft seal rings with pe
(21) Measure inside diameter of bushing in clutch troleum jelly. Before installing drum shaft seal rings,
drum hub. Maximum allowable diameter is 24.08 squeeze each ring so ring ends overlap (Fig. 14). This
mm (0.9480 in.). Replace clutch drum if bushing in tightens ring making clutch installation easier.
side diameter is greater than specified. (3) Install seal rings on shaft. Keep rings closed as
tightly as possible during installation. Avoid over
FORWARD CLUTCH ASSEMBLY spreading them.
(1) Lubricate bearing and race assembly with pe (4) Mount clutch drum on overdrive support.
troleum jelly and install it in clutch drum (Fig. 13). (5) Lubricate and install new O-ring on clutch
drum hub (Fig. 7).
CLUTCH
DISCS
Fig. 15 Installing Forward Clutch Discs And Plates

Fig. 14 Installing Clutch Drum Shaft Seal Rings
(6) Lubricate and install new O-rings on clutch
piston and install piston in drum.
(7) Install piston return springs.
and shop press and install piston snap ring. Be sure
snap ring end gap is not aligned with any notches in
drum.
(9) Install cushion plate in drum. Concave side of
plate faces downward (Fig. 5).
(10) Install clutch discs, plates and retainer (Fig.
15). Install tabbed plate followed by disc until re
quired number of plates and discs are installed. Use
six plates and discs.
(11) Install clutch pack snap ring.
(12) Recheck clutch piston stroke length using
same method outlined at beginning of disassembly
procedure. If stroke length is not within specified
limits, replace clutch discs.
J8921-581
(13) Lubricate race and bearing with petroleum
jelly and install them in clutch drum (Fig. 16). Be Fig. 16 Installing Thrust Bearing And Race
sure bearing rollers face up and race lip seats in
drum as shown.
(14) Verify bearing and race size.
• Outer diameter of bearing is 46.7 mm (1.839 in).
• Outer diameter of race is 48.9 mm (1.925 in.).
• Inner diameter of bearing and race is 26.0 mm
(1.024 in.).
(15) Mount forward clutch on direct clutch and
check assembled height (Fig. 17). Height should be
70.3 - 71.5 mm (2.767 - 2.815 in.).
AW-4 TRANSMISSION OVERHAUL 2 1 - 219
J (4) Remove snap ring attaching planetary gear to
shaft and remove gear.
(5) Remove rear bearing and race from planetary
gear.
DIRECT
(6) Measure inside diameter of ring gear bushing.
CLUTCH Maximum allowable diameter is 24.08 mm (0.9480
in.). Replace ring gear if bushing inside diameter is
FRONT PLANETARY ASSEMBLY

(1) Lubricate planetary and ring gear bearings and
races with petroleum jelly.
(2) Identify planetary bearings and races before in
stallation. (Fig. 1). Bearings and races can be identi
fied by following dimensions:
• Outer diameter of rear bearing is 47.7 mm (1.878
in.). Inner diameter is 35.5 mm (1.398 in.).
• Outer diameter of rear race 47.6 mm (1.874 in.).
FORWARD Inner diameter is 33.7 mm (1.327 in.).
CLUTCH-
J8921-582 • Outer diameter of front race is 53.6 mm (2.110
in.). Inner diameter is 30.5 mm (1.201 in.).
Fig. 17 Checking Forward Clutch Assembled Height • Outer diameter of front bearing is 47.7 mm (1.878
FRONT PLANETARY GEAR OVERHAUL in.). Inner diameter is 32.6 (1.283 in.).
• Outer diameter of forward race is 47.0 mm (1.850
FRONT PLANETARY DISASSEMBLY in.). Inner diameter is 26.5 mm 1.043 in.).
(1) Remove ring gear from planetary gear (Fig. 1). (3) Install rear race and bearing in gear (Fig. 2).
(2) Remove front bearing and the two races from (4) Turn planetary over and install race thrust
ring gear (Fig. 1). race (Fig. 3).
(3) Remove tabbed thrust race from planetary gear
(Fig. 1).
F R O N T PLANETARY RING GEAR
FORWARD S N A P RING REAR

RACE RACE
REAR
BEARING
F R O N T PLANETARY GEAR
J8921-583
Fig. 1 Front Planetary Gear Components

21 - 2 2 0 AW-4 TRANSMISSION OVERHAUL J
Fig. 4 installing Front Planetary Front Rearing And

Races
SUN GEAR AND NO. 1 ONE-WAY CLUTCH
OVERHAUL
SUN GEAR AND CLUTCH DISASSEMBLY
(1) Hold sun gear and turn second brake hub
clockwise and counterclockwise (Fig. 2). Hub should
rotate freely clockwise but lock when turned counter
clockwise. Replace one-way clutch and hub if they do
not operate properly.
1 1
— — J9121-399
Fig. 3 Installing Front Planetary Thrust Race

(5) Install front race and bearing and forward race
in ring gear (Fig. 4).
(6) Set planetary gear assembly aside for final as
sembly.
SEAL RINGS
J9121-400
Fig. 1 Sun Gear And One-Way Clutch Components

SECOND HUB AND
Assembly
Fig. 2 Checking One-Way Clutch Operation
(2) Remove one-way clutch/second brake hub as
sembly from drum (Fig. 3 ) .
(3) Remove thrust washer from drum (Fig. 4 ) .
(4) Remove two seal rings from sun gear (Fig. 5 ) .
(5) Support sun gear on wood block (Fig. 6 ) . Then
remove first sun gear snap ring and separate drum
from gear.
Fig. 4 Removing/Installing Thrust Washer

SEAL
RINGS (2)
Fig. 6 Removing/Installing Sun Gear
Fig. 7 Removing/Installing Second Snap Ring

SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
J8921-591 (2) Install sun gear in drum and install remaining
snap ring.
Fig. 5 Removing/Installing Sun Gear Seal Rings (3) Coat replacement seal rings with petroleum
(6) Remove remaining snap ring from sun gear jelly and install them on sun gear. Be sure seal
(Fig. 7). ring ends are interlocked,
(7) Measure inside diameter of sun gear bushings (4) Install thrust washer. Be sure washer tabs are
with bore gauge or inside micrometer (Fig. 8). Maxi seated in drum slots.
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
CLUTCH
AND HUB
ASSEMBLY
Fig. 8 Checking Sun Gear Bushings

(5) Install one-way clutch/second brake hub assem
bly on sun gear. Deep side of hub flange faces up
J8921-595
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2). Fig. 9 Installing Clutch And Hub Assembly On Sun
Hold sun gear and turn second brake hub clockwise Gear
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise. SECOND BRAKE OVERHAUL
(7) Set sun gear/clutch assembly aside for final as
sembly. BRAKE DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fig. 2).
(2) Set output shaft assembly aside for overhaul.
Refer to Rear Planetary Gear and Output Shaft
Overhaul procedures.
(3) Remove thrust washer from second brake drum
(Fig. 3).
REAR PLANETARY/OUTPUT S H A F T /
FIRST-REVERSE BRAKE
SECOND
BRAKE D R U M
^SECOND BRAKE PISTON

J8921-596
Fig. 1 Second Brake Components

21 - 224 AW-4 TRANSMISSION OVERHAUL tf
S E C O N D BRAKE
ASSEMBLY
J8921-597
Fig. 2 Removing/installing Second Brake Assembly
Fig. 4 Removing/Installing Second Brake Piston

Snap Ring
PISTON
AND
SLEEVE
Fig. 3 Removing/Installing Second Brake Drum J8921-600

Thrust Washer
(4) Compress piston return springs with shop press Fig. 5 Removing/Installing Piston And Sleeve
and tool 7538. Then remove piston snap ring (Fig. 4). SECOND BRAKE ASSEMBLY
(5) Remove compressor tool and remove spring re (1) Lubricate and install new O-rings on brake pis
tainer and return springs. ton. Then install brake piston in drum.
(6) Remove second brake piston and sleeve from (2) Install return springs and retainer on brake
drum with compressed air (Fig. 5). Use only enough piston.
air pressure to ease piston out of drum. (3) Compress return springs with shop press and
(7) Remove and discard brake piston O-rings. Compressor Tool 7538. Install piston snap ring and
(8) Measure free length of piston return springs remove brake assembly from press.
with springs mounted in retainer (Fig. 6). Length (4) Check brake piston operation with low pressure
should be approximately 16.05 mm (0.632 in.). Re compressed air (Fig. 7). Apply air pressure through
place return springs if length is less than specified. feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.
(5) Coat thrust washer with petroleum jelly and

install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
THRUST
WASHER
NOTCHES
J8921-536
Fig. 6 Measuring Second Brake Piston Return SPRING

Springs RETAINER
TABS
PISTON
J8921-602
Fig. 8 Installing Second Brake Thrust Washer

REAR PLANETARY, NO. 2 ONE-WAY CLUTCH AND
OUTPUT SHAFT OVERHAUL
PLANETARY/BRAKE PACK/OUTPUT SHAFT
DISASSEMBLY
(1) Remove output shaft from gear assembly (Fig.
2).
(2) Remove and discard shaft seal ring (Fig. 4).
DRUM
J8921-601
Fig. 7 Checking Second Brake Piston Operation

REAR PLANETARY GEAR
J8921-603
Fig. 1 Rear Planetary, Brake Pack, Clutch And Output Shaft Components
J8921-604 E N D S INTERLOCK
Fig. 2 Removing/Installing Output Shaft

9
* J8921-605
(3) Remove brake pack from planetary gear (Fig.
4). Fig. 3 Removing/Installing Shaft Seal Ring
(4) Measure thickness of each brake pack disc.
FIRST-REVERSE
BRAKE
PACK
PLANETARY
GEAR
J8921-606 J8921-608
Fig. 4 Removing/installing First-Reverse Brake Pack Fig. 6 Checking No. 2 One-Way Clutch Operation
Minimum thickness is 1.51 mm (0.0594 in.). Replace
all discs if any disc is thinner than specified.
(5) Remove planetary gear from ring gear (Fig. 5).
(6) Check No. 2 one-way clutch. Hold planetary
Fig. 7 Removing/Installing Clutch Inner Race

(8) Remove clutch snap ring and remove No. 2 one
way clutch from planetary (Fig. 8).
(9) Remove front and rear thrust washers from
Fig. 5 Removing/Installing Rear Planetary planetary gear (Fig. 9).
gear and turn clutch inner race in both directions.
Race should turn freely counterclockwise, but lock
when turned clockwise. Replace one-way clutch if
necessary.
(7) Remove clutch inner race from planetary gear
(Fig. 7).
FRONT REAR
THRUST THRUST
WASHER WASHER
J8921-611
Fig. 9 Removing/Installing Rear Planetary Thrust

Washers
THRUST
BEARING
Fig. 8 Removing.instalHng One-Way Clutch

(10) Remove thrust bearing and washers from ring
gear (Fig. 10).
(11) Remove ring gear snap ring and remove ring
gear hub (Fig. 11).
(12) Inspect and replace any worn or damaged J892T-612
planetary gear components.
Fig. 10 Removing/Installing Ring Gear Thrust
ASSEMBLING REAR PLANETARY, BRAKE Bearing And Races
PACK, CLUTCH AND SHAFT (3) Lubricate ring gear thrust bearing and races
(1) Install hub and snap ring in ring gear (Fig. 11) with petroleum jelly and install them in ring gear
(2) Identify ring gear thrust bearing and races by (Fig. 10).
following dimensions (Fig. 10): (4) Coat planetary thrust washers with petroleum
• Outer diameter of bottom race is 44.8 mm (1.764 jelly and install them in gear (Fig. 9).
in.) and inner diameter is 27.6 mm (1.087 in.). (5) Install No. 2 one-way clutch in planetary gear.
• Outer diameter of bearing is 44.7 mm'(1.760 in.) Be sure flanged side of clutch faces upward (Fig. 12).
and inner diameter is 30.1 mm (1.185 in.). (6) Install clutch retaining snap ring and install
• Outer diameter of upper race is 44.8 mm (1.764 clutch inner race (Fig. 7). Turn race counterclockwise
in.) and inner diameter is 28.8 mm (1.134 in.). to ease installation.
FLANGED SIDE
O F CLUTCH
SNAP
RING
NO. 2 ONE-WAY
CLUTCH
HUB REAR
PLANETARY
J8921-614
RING Fig. 12 Installing No. 2 One-Way Clutch

GEAR
(10) Install brake pack on planetary gear (Fig. 4).
(11) Install new seal ring on output shaft (Fig. 3).
Be sure ring ends are interlocked as shown.
(12) Set assembled components aside for final as
sembly.
_ _ J8921-613
Fig. 11 Removing/installing Ring Gear Hub FIRST-REVERSE BRAKE PISTON AND

TRANSMISSION CASE OVERHAUL
(7) Verify one-way clutch operation. Hold gear and
turn inner race in both directions. Race should turn BRAKE DISASSEMBLY AND INSPECTION
freely counterclockwise, but lock when turned clock (1) Remove bearing and race assembly from trans
wise. mission case (Fig. 2).
(8) Install planetary gear in ring gear. (2) Check first/reverse brake piston operation with
(9) Assemble clutch discs and clutch plates (Fig. 4). compressed air (Fig. 3). Piston should move smoothly
Sequence is disc first, then a plate. Use seven discs and not bind or stick. If piston operation is incorrect,
and plates in a 6-cyl. transmission. case or piston may require replacement.
RETAINER
TRANSMISSION
PLATE CASE
REACTION SLEEVE
PISTON R E T U R N
SPRING
BEARING
FIRST-REVERSE A N D RACE
BRAKE PACK ASSEMBLY
N O . 1 FIRST-REVERSE
BRAKE P I S T O N
N O . 2 FIRST-REVERSE
BRAKE P I S T O N
S N A P RING
J8921-615
Fig. 1 First-Reverse Brake Pistons And Transmission Case

COMPRESSOR
TOOL
J8921-616
J8921-618
Fig. 2 Removing/Installing Bearing And Race Fig. 4 Removing/Installing Piston Snap Ring
Assembly
TOOL
8.VLFM-31
REACTION
J8921-619
Fig. 5 Removing/Installing Reaction Sleeve

(7) Remove No. 1 first/reverse brake piston with
Piston Puller 7543 (Fig. 6). Slip tool under piston
Fig. 3 Checking First-Reverse Brake Piston and lift tool and piston out of case.
Operation (8) Measure free length of piston return springs
(3) Compress piston return springs with Tool 7539 with springs mounted in retainer. Length should be
and remove piston snap ring (Fig. 4). 18.382 mm (0.724 in.). Replace springs if length is
(4) Remove Tool 7539 and remove piston return less than this.
springs. (9) Clean transmission case thoroughly with sol
(5) Remove No. 2 first-reverse brake piston with vent and dry it with compressed air. Blow com
compressed air. Apply air through same transmission pressed air through oil feed passages to remove
feed hole used for checking piston operatiqn. solvent residue and ensure that passages are clear.
(6) Remove reaction sleeve with Sleeve Remover Inspect the case for wear or damage. Replace case if
Tool 7542 (Fig. 5). Insert tool flanges under sleeve necessary.
and lift tool and sleeve out of case.
TOOL NO. 1 P I S T O N
B.Vi.FM-32 AND
REACTION SLEEVE
NO.2
PISTON
J8921-622
J8921-620
Fig. 8 Assembling First-Reverse Brake Pistons

Fig. 6 Removing/installing First-Reverse Brake No.1
Piston TRANSMISSION
CASE
ASSEMBLING FIRST/REVERSE BRAKE
PISTON
(1) Lubricate and install new O-rings on No. 1
first/reverse brake piston and on reaction sleeve (Fig.
7). Then install piston in sleeve.
NO. 1 REACTION
PISTON SLEEVE
J8921-623
Fig. 9 Installing First-Reverse Brake Piston

Assembly
and install piston snap ring (Fig. 4). Be sure snap
J8921-621
ring end gap is not aligned with any tangs on return
Fig. 7 Assembling No. 1 Piston And Sleeve spring retainer.
(7) Verify piston operation with compressed air as
(2) Lubricate and install new O-ring on No. 2 outlined in disassembly procedure.
brake piston. (8) Coat bearing and race assembly with petroleum
(3) Install assembled No. 1 piston and reaction jelly and install it in piston assembly (Fig. 2). Bear
sleeve on No. 2 piston (Fig. 8). ing and race assembly outer diameter is 57.7 mm
(4) Lubricate and install piston assembly in case (2.272 in.) and inner diameter is 39.2 mm (1.543 in.).
(Fig. 9). Align piston and case slots and press piston
assembly into case with hand pressure.
(5) Position piston return springs on No. 2 piston.
TRANSMISSION VALVE BODY OVERHAUL
The valve body assembly consists of two sections
which are the upper body and lower body (Figures 1
and 2). Disassembly, inspection and overhaul proce
dures for each section are outlined separately. Refer
to the appropriate procedure as needed.
SLEEVE
J9121-384
Fig. 1 Lower Body Components

PLUG L O W COAST M O D U L A T O R
2-3 SHIFT VALVE VALVE A N D SPRING
A N D SPRING
CUT-BACK VALVE
A N D SPRING THROTTLE
VALVE
ADJUSTING
RINGS A N D SPRING
SECONDARY
REGULATOR
VALVE A N D SPRING
S E C O N D COAST M O D U L A T O R
VALVE A N D SPRING
PLUG
CHECK BALLS
T H R O T T L E VALVE PIN DOWNSHIFT

A N D SPRING PLUG
J8921-625
Fig. 2 Upper Body Components

REMOVING UPPER BODY FROM LOWER BODY ^ = BOLT LOCATIONS

(1) Remove two-piece detent spring (Fig. 3). Note
position of spring sections for assembly reference.
od:q J8921-628
Fig. 5 Valve Body Bolt Locations
UPPER
BODY
J8921-626
PLATE
Fig. 3 Removing/Installing Detent Spring AND LOWER
GASKETS BODY J8921-629
(2) Remove manual valve from lower body (Fig. 4).
(3) Remove bolts attaching upper body to lower Fig. 6 Upper Body, Plate And Gaskets
LOWER CHECK CHECK B A L L
BODY VALVE A N D SEAT LONG
AND STRAINER
SPRING
-MANUAL
VALVE
J8921-627
Fig. 4 Removing/installing Manual Valve

body (Fig. 5).
(4) Carefully lift and remove upper body, plate and
PRESSURE
gaskets from lower body (Fig. 6).
RELIEF VALVE SHORT
(5) Disassemble and overhaul upper and lower AND SPRING STRAINERS J9121-416
body sections as outlined in following procedures.
Fig. 1 Lower Body Check Valve And Strainer
LOWER BODY DISASSEMBLY Location
(1) Remove check valve and spring, pressure relief
(3) Note or mark position of valve retainers and
valve and spring and ball check and seat from lower
pressure reducing plug clip for assembly reference
body. Note location of each valve for assembly refer
(Fig. 2). Do not remove the retainers at this time.
ence (Fig. 1).
(4) Remove solenoid No. 1 , 2 and 3. Discard sole
(2) Remove oil strainers (Fig. 2).
noid O-rings.
(5) Remove 1-2 shift valve retainer (Fig. 3).
VALVE
RETAINERS
Fig. 4 Removing/Installing 1-2 Shift Valve

VALVE REDUCING
RETAINER PLUG CLIP (a) Note position of valve retainer for assembly
J8921-632 reference (Fig. 5). Then press valve sleeve inward
with your thumb and remove retainer with mag
Fig. 2 Valve Retainer And Clip Location net.
(6) Remove 1-2 shift valve plug, valve spring and REGULATOR
valve (Fig. 4).
Fig. 3 Removing 1-2 Shift Valve Retainer

J8921-635
(7) Remove primary regulator valve as follows:
Fig. 5 Regulator Valve Retainer Position
WARNING: THE PRIMARY REGULATOR VALVE
(b) Slowly release thumb pressure on sleeve and
SLEEVE AND PLUNGER ARE UNDER TENSION
remove sleeve, spring and washer and valve (Fig.
FROM THE VALVE SPRING. EXERT COUNTER-
6). Use magnet to remove valve i f necessary.
PRESSURE ON THE SPRING WHILE REMOVING
THE VALVE RETAINER TO PREVENT COMPO
NENTS FROM FLYING OUT.
J
J8921-636
Fig. 6 Removing/installing Primary Pressure

Regulator Valve
(8) Remove regulator valve plunger from sleeve
(Fig. 7).
VALVE
J8921-638
Fig. 8 Removing/Installing Pressure Reducing Plug
J8921-637
Fig. 7 Removing/Installing Regulator Valve Plunger

(9) Remove retaining clip and remove pressure re
ducing plug (Fig. 8). Cover screwdriver blade with
tape to avoid scratching valve body surface.
( 1 0 ) Remove accumulator control valve retainer
and remove control valve assembly (Fig. 9 ) .
J8921-639
Fig. 9 Removing/Installing Accumulator Control

Valve Assembly
J AW-4 T R A N S M I S S I O N OVERHAUL 2 1 - 237
(11) Remove spring and control valve from valve (2) Install spring and accumulator control valve in
sleeve (Fig. 10). sleeve (Fig. 11). Then install assembled components
in lower body (Fig. 9).
(3) Press accumulator control valve assembly into
valve bore and install retainer (Fig. 9).
(4) Install pressure reducing plug in plug bore.
Then secure plug with retaining clip (Fig. 8).
(5) Install washer on primary regulator valve
plunger (Fig. 12).
(6) Install primary regulator valve plunger in
J8921-640
valve sleeve (Fig. 7).
(7) Install valve spring and regulator valve sleeve
F i g . 10 Accumulator Control Valve Components and plunger.
(8) Press regulator valve sleeve into bore and in
(12) Clean lower body valve components with sol stall retainer (Fig. 5 and 6). Be sure retainer is posi
vent and dry them with compressed air only. Do not tioned in sleeve lugs as shown.
use shop towels or rags. Lint or foreign material (9) Install 1-2 shift valve, spring and plug (Fig. 4).
from towels or rags can interfere with valve opera Then press valve assembly into bore and install re
tion. tainer.
(13) Inspect condition of lower body components. (10) Install replacement O-rings on solenoids and
Replace lower body if any bores are scored or cor install solenoids on valve body. Tighten solenoid at
roded. Replace valves, plugs or sleeves that are taching bolts to 10 N»m (7 ft-lbs) torque.
scored or worn. Replace oil strainers if cut, torn or (11) Install oil strainers (Fig. 13). Identify strain
damaged in any way. ers before installation. The three strainers are
(14) Inspect valve body springs. Replace any spring all the same diameter but are different lengths.
having rusted, distorted, or collapsed coils. Measure Two strainers are 11.0 mm (0.443 in.) long while
length of each valve body spring. Replace any spring one strainer is 19.5 mm (0.76 in.) long (Fig. 14).
if free length is less than length specified in follow
ing chart (Fig. 11).
LOWER BODY ASSEMBLY

(1) Lubricate lower body components with auto
matic transmission fluid.
Spring Free Length
(A) Check Valve 20.2 mm (0.801 in.)
(B) Pressure Relief Valve 11.2 mm (0.441 in.)
{ Q l - 2 Shift Valve 30.8 mm (1.213 in.)
(D) Primary Regulator Valve 62.3 mm (2.453 in)
(E) Accumulator Control Valve 29.8 mm (1.173 in)
F i g . 11 Lower Body Valve Spring Dimensions

UPPER BODY DISASSEMBLY AND

INSPECTION
(1) Remove valve body plate and gaskets (Fig. 1).
Discard gaskets.
UPPER BODY
PLATE A N D
GASKETS
J8921-644
Fig. 1 Removing/Installing Upper Body Plate And

Gaskets
PRIMARY (2) Remove strainer and eight check balls (Fig. 2).
REGULATOR
VALVE PLUNGER
Note check ball and strainer position for assembly
reference.
J8921-642
Fig. 12 Installing Washer On Regulator Valve

Plunger
(12) Install check valve and spring (Fig. 13).
(13) Install check ball and seat (Fig. 13).
(14) Install pressure relief valve and spring (Fig.
13).
CHECK LONG
VALVE STRAINER
AND
SPRING
OIL
STRAINER
CHECK B A L L DIAMETER
® 6.35 mm (.250 in.)
(D 5.535 mm (.218 in.) J9121-415
PRESSURE Fig. 2 Check Ball And Strainer

RELIEF VALVE SHORT Location/Identification
A N D SPRING STRAINERS J9121-419
(3) Remove valve stop and throttle cam (Fig. 3).
Fig. 13 Oil Strainer And Check Valve Installation
J AW-4 TRANSMISSION OVERHAUL 21 - 2 3 9
J8921-646
Fig. 3 Removing/installing Valve Stop And Throttle

Cam
(4) Remove throttle valve pin with magnet and re
move downshift plug, valve spring and throttle valve
(Fig. 4).
(5) Turn upper body over and remove throttle
valve adjusting rings and spring (Fig. 5). Note num
ber of adjusting rings if valve is equipped with them.
(6) Remove 3-4 shift valve retainer with magnet
and remove valve plug, spring and 3-4 shift valve
(Fig. 6).
(7) Remove second coast modulator valve retainer
and remove valve plug, spring and valve.
(8) Remove lock-up relay valve retainer and re
move relay valve and sleeve assembly (Fig. 8).
(9) Remove relay valve, spring and plunger from
valve sleeve (Fig. 9).
(10) Remove secondary pressure regulator valve
retainer and remove plug, regulator valve and spring
(Fig. 10).
(11) Remove cut-back valve retainer and remove
J8921-648
plug, cut-back valve and spring (Fig. 11).
(12) Remove 2-3 shift valve retainer and remove Fig. 5 Throttle Valve Adjusting Ring Location (If
plug, spring and 2-3 shift valve (Fig. 12). Equipped)
(13) Remove low coast modulator valve retainer
and remove valve plug, spring and low coast modu
lator valve (Fig. 13).
J
VALVE
J8921-649 J8921-651
Fig. 6 Removing/Installing 3-4 Shift Valve Fig. 8 Removing/Installing Converter Clutch Relay
Valve
J8921-652
Fig. 9 Relay Valve Components

(14) Clean the upper body components with solvent
and dry them with compressed air only. Do not use
shop towels or rags. Lint or foreign material from
towels or rags can interfere with valve operation.
Fig. 7 Removing/Installing Second Coast Modulator
Valve
VALVE.
SPRING
SECONDARY
PRESSURE
REGULATOR VALVE.
VALVE V A L V E
PLUG SPRING
J8921-653 J8921-655
Fig. 10 Removing/installing Secondary Pressure Fig. 12 Removing/Installing 2-3 Shift Valve

Regulator Valve
VALVE
RETAINER
VALVE
PLUG
LOW COAST/
MODULATOR
VALVE VALVE
SPRING
J8921-656
CUT-BACK.
VALVE Fig. 13 Removing/Installing Low Coast Modulator
J8921-654
Valve
Fig. 11 Removing/Installing Cut-Back Valve
(15) Inspect condition of the upper body compo (16) Inspect the valve body springs. Replace any
nents. Replace the upper body if any of the bores are spring having rusted, distorted, or collapsed coils.
scored or corroded. Replace any valves, plugs or Measure length of each spring. Replace any spring if
sleeves if scored or worn. Replace the oil strainer if free length is less than specified in the chart (Fig.
cut, torn or damaged in any way. 14).
UPPER BODY ASSEMBLY

(1) Lubricate the valves, springs, plugs, sleeves
and the valve bores in the upper body with auto
(2) Note position of the valve retainers (A) and
stop (B) for assembly reference (Fig. 15).
(3) Install low coast modulator valve, spring and
plug in valve bore. Press valve plug inward and in
stall retainer (Fig. 13).
A--0 00--c=DOQ []- = J
®
i-tzzgn=n>—do Spring Free Length
(A) Downshift Plug 27.3 mm (1.074 in.)
(B) ThrotHe Valve 20.6 mm (0.811 in.)
(C) 3 - 4 Shift Valve 30.8 mm (1.212 in.)
(D) Second Coast Modulator Valve 25.3 mm (0.996 in.)
(E) Lockup Relay Valve 21.4 mm (0.843 in)
(F) Second Regulator Valve 30.9 mm (1.217 in.)

(j~]-Q={~]i- - mm--=gso- i
(G) Cut-Back Valve 21.8 mm (0.858 in.)
(H) 2-3 Shift Valve 30.8 mm (1.212 in.)
© (J) Low Coast Modulator Valve 27.8 mm (1.094 in.)
•VVXiV.\.V\\? I - - D O - - Ml
As Dfl
o o = - - wmm--do J8921-657
Fig. 14 Upper Body Spring/Valve Identification

A - VALVE RETAINERS (9) Install second coast modulator valve, spring

and plug in valve bore. Press plug inward and install
retainer (Fig. 7).
(10) Install 3-4 shift valve, spring and plug in
bore. Press plug inward and install retainer (Fig. 6).
(11) Install throttle valve in valve bore. Push
valve into place and install valve stop (Fig. 16).
(12) On models with adjusting rings, turn upper
body over and install adjusting rings (Fig. 17). Be
sure to install same number of rings as were re
moved.
(13) Install throttle valve adjusting spring in bore
and onto end of throttle valve (Fig. 18).
ADJUSTING
J8921-658
F i g . 15 Valve Retainer And Stop Locations

(4) Install 2-3 shift valve, spring and plug in valve
bore. Press plug inward and install retainer (Fig. 12).
(5) Install cut-back valve spring, valve and plug
(Fig. 11). Press plug inward and install retainer.
(6) Install secondary regulator valve spring, valve
and plug in valve bore. Press plug inward and install
retainer (Fig. 10).
(7) Assemble lock-up relay valve. Install spring J8921-660
and plunger in valve sleeve (Fig. 9). Then install as
sembled valve in sleeve. F i g . 17 Install Throttle Valve Adjusting Rings (If
(8) Install assembled lock-up relay valve in valve Equipped)
bore and install retainer (Fig. 8).
J8921-661
THROTTLE F i g . 18 Installing Throttle Valve Adjusting Spring

VALVE
(14) Install downshift spring and plug in throttle
J8921-659 valve bore. Press plug inward against throttle valve
and spring and install retainer pin (Fig. 19).
F i g . 16 Installing Throttle Valve And Stop (15) Install sleeve in throttle cam (Fig. 20).
(16) Install spring on cam (Fig. 20). Hook curved

end of spring through hole in cam as shown.
(17) Mount cam on upper body and install cam at
taching bolt and spacer (Fig. 20). Tighten bolt to 10
N»m (7 ft. lbs.) torque.
(18) Be sure straight end of spring is seated in up
per body slot as shown (Fig. 20).
(19) Install check balls in upper body (Fig. 2).
(20) Install oil strainer (Fig. 2).
INSTALLING UPPER BODY ON LOWER BODY

If valve body was equipped with gaskets, start at
step (1). However, if valve body is not equipped with
RETAINING
gaskets, start at step (4).
(1) Position new No. 1 gasket (Fig. 1) on upper
body.
J8921-662
(2) Position valve body plate on No. 1 gasket.
(3) Position new No. 2 gasket (Fig. 2) on valve
Fig. 19 Installing Downshift Plug body plate and align gaskets and plate using bolt
holes as guides.
J8921-665
Fig. 1 Valve Body Gasket No. 1
J8921-666
Fig. 2 Valve Body Gasket No. 2

(4) Install valve body bolts. Three different
length bolts are used. Refer to the Figure 3 for
bolt locations. Chart symbols indicate bolt loca
tion and length in millimeters.
(5) Tighten valve body bolts to 6.4 N*m (56 in. lbs.)
torque.
(6) Install manual valve (Fig. 4).
(7) Install two-piece detent spring (Fig. 5). Tighten
spring attaching bolt to 10 N m (7 ft. lbs.) torque.
s
J8921-663
Fig. 20 Installing Throttle Cam
DETENT
SPRING
O 3 3 mm
(1.5 in.)
2 0 mm
(0.787 in.)
2 8 mm
(1.10 in.)
J8921-667 J8921-626
Fig. 3 Vaive Body Bolt Location/Size Fig. 5 Installing Detent Spring

LOWER
BODY
-MANUAL
VALVE
J8921-627
Fig. 4 Installing Manual Valve

OVERDRIVE
PLANETARY GEAR
A N D DIRECT
OIL CLUTCH
PUMP
CONVERTER
HOUSING
TORQUE OVERDRIVE
CONVERTER CLUTCH
PACK
REAR PLANETARY
GEAR, S E C O N D BRAKE
DRUM, FIRST-REVERSE
BRAKE PACK A N D
OUTPUT SHAFT
ASSEMBLY
PARK
LOCK
COMPONENTS
J8921-668
Fig. 1 AW-4 Transmission Components

J (4) Install rear planetary gear, second brake drum
TRANSMISSION ASSEMBLY AND ADJUSTMENT
(1) During assembly, lubricate components with and output shaft as outlined in following steps:
transmission fluid or petroleum jelly as indicated. (5) Verify No. 10 thrust bearing and race (Fig. 2).
(2) If any of the transmission components are still Bearing and race outer diameter is 57.7 mm (2.272
assembled after overhaul checking procedures, disas in.) and inside diameter is 39.2 mm (1.543 in.).
semble as necessary in preparation for transmission (6) Coat thrust bearing and race assembly with pe
assembly. troleum jelly and install in case (Fig. 3). Race faces
(3) Verify thrust bearing and race installation dur down. Bearing rollers face up.
ing assembly. Refer to the Thrust Bearing Chart (7) Align teeth of second brake drum and clutch
(Fig. 2) for bearing and race location and correct po pack (Fig. 4).
sitioning.
© © © © © © © © ® ®
S t 1 I 1 J 1
S
I It 1 1
J8921-669
Fig. 2 Thrust Bearing Chart

FRONT THRUST
BEARING
AND
RACE
CASE
SLOTS
ALIGN
CLUTCH/DRUM
TEETH
WITH
CASE
SLOTS J8921-672
Fig. 5 Installing Output Shaft And Rear Planetary

Assembly
J8921-670
(9) Install rear planetary snap ring with snap ring
Fig. 3 Installing Thrust Bearing And Race (No. 10) pliers. Chamfered side of snap ring faces up and to
ward case front (Fig. 6).
SECOND
BRAKE
DRUM
CLUTCH
" PACK
ALIGN
DRUM AND REAR PLANETARY
CLUTCH PACK S N A P RING
TEETH
J8921-671
J8921-673
Fig. 4 Aligning Second Brake Drum And Clutch
Pack Teeth Fig. 6 Installing Planetary Snap Ring
(8) Align rear planetary-output shaft assembly (10) Check first-reverse brake pack clearance with
teeth with case slots and install assembly in case feeler gauge. Clearance should be 0.70 - 1.20 mm
(Fig. 5). (0.028 - 0.047 in.). If clearance is incorrect, planetary
assembly, thrust bearing or snap ring is not properly
seated in case. Remove and reinstall components if
necessary.
J9121-382
Fig. 9 Installing Second Brake Drum Gasket

J8921-674
Fig. 7 Checking First-Reverse Brake Pack Clearance
J8921-675 Fig. 10 Installing Park Lock Pin, Spring And Pawl

(14) Connect park lock rod to manual valve shift
Fig. 8 Installing Second Brake piston Sleeve
sector (Fig. 11).
(11) Install second brake piston sleeve (Fig. 8). (15) Position park lock rod bracket on case and
Sleeve lip faces up and toward case front as shown. tighten bracket attaching bolts to 10 N®m (7 ft. lbs.)
(12) Install second brake drum gasket with In torque (Fig. 12).
staller Tool 7544 (Fig. 9). Gasket depth is 43.7 mm (16) Verify park lock operation. Move shift sector
(1.720 in.). to Park position. Park pawl should be firmly engaged
(13) Install park lock pawl, spring and pin (Fig. (locked) in planetary ring gear (Fig. 13).
10).
- 250 AW-4 TRANSMISSION OVERHAUL J
SHIFT (17) Install No. 1 one-way clutch (Fig. 14). Short

flanged side of clutch faces up and toward case front.
(18) Install second brake pack (Fig. 15). Install
^ FRONT
Fig. 14 Installing No. 1 One-Way Clutch

disc then plate. Continue installation sequence until
correct number of discs-plates are installed. Use five
discs and five plates.
J8921-679
Fig. 12 Installing Park Rod Bracket
Fig. 15 Installing Second Brake Pack

(19) Install second brake pack retainer with
rounded edge of retainer facing disc.
(20) Install second brake pack snap ring.
J8921-680
(21) Check brake pack clearance with feeler gauge
(Fig. 16). Clearance should be 0.062 - 1.98 mm (0.024
Fig. 13 Checking Park Pawl Engagement
- 0.078 in.). If brake pack clearance is not correct, (23) Install front planetary gear on sun gear (Fig.
brake pack components are not seated. Reassemble 18).
brake pack if necessary.
FRONT
PLANETARY
J8921-683
Fig. 16 Checking Second Brake Pack Clearance

(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are Fig. 18 Installing Front Planetary Gear
seated in drum. Use petroleum jelly to hold thrust (24) Support output shaft with wood blocks (Fig.
washer in position if necessary. 19).
BLOCKS
J8921-686
Fig. 19 Supporting Output Shaft

Fig. 17 Installing Sun Gear And Input Drum
(25) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 20).
(26) Install tabbed thrust race on front planetary
gear (Fig. 21). Washer tabs face down and toward
gear. Race outer diameter is 47.8 mm (1.882 in.). In
side diameter is 34.3 mm (1.350 in.).
S N A P RING SECOND
PLIER T O O L COAST
BRAKE
BAND
FRONT
PLANETARY
SNAP
RING
J8921-687 J8921-689
Fig. 22 Installing Second Coast Brake Band
Fig. 20 installing Front Planetary Snap Ring
FRONT
PLANETARY
GEAR
S E C O N D COAST
BRAKE BAND BAND
RETAINING
PIN
J8921-688
Fig. 21 installing Planetary Thrust Race RETAINING RING

(INSTALL O N PIN)
(27) Install second coast brake band (Fig. 22).
(28) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 23).
( 2 9 ) Install thrust bearing and race in forward-di
rect clutch (Fig. 24). Coat bearing/race with petro
leum jelly to hold them in place.
(30) Verify forward-direct clutch thrust bearing
size.
• Race outer diameter is 48.9 mm (1.925 in.) and in
side diameter is 26.0 mm (1.024 in.).
* Bearing outer diameter is 46.7 mm (1.839 in.) and
inside diameter is 26.0 mm (1.024 in.). J8921-690
Fig. 23 Installing Second Coast Brake Band
Retaining Pin
troleum jelly and install it in ring gear (Fig. 25).

(32) Verify ring gear race size. Outer diameter is
THRUST 47.0 mm (1.850 in.) and inside diameter is 26.5 mm
BEARING
(1.045 in.).
(33) Align forward-direct clutch disc splines with
screwdriver (Fig. 26).
(34) Align and install front planetary ring gear in
forward-direct clutch (Fig. 27).
^ FRONT FORWARD-DIRECT
CLUTCH ASSEMBLY
RING
GEAR
J8921-691
Fig. 24 Installing Forward-Direct Clutch Thrust

Bearing And Race
THRUST
J8921-694
RACE
J8921-692 Fig. 27 Installing Front Planetary Ring Gear

(35) Coat bearing and race with petroleum jelly
Fig. 25 Installing Planetary Ring Gear Race and install them in ring gear (Fig. 28). Verify bear
ing/race size.
CLUTCH SPLINE
ALIGNING T O O L
PLANETARY
RING GEAR
THRUST
BEARING
FORWARD-DIRECT
CLUTCH
J8921-693
J8921-695
Fig. 26 Aligning Forward-Direct Clutch Splines
(31) Coat front planetary ring gear race with pe Fig. 28 Installing Ring Gear Bearing And Race
• Bearing outer diameter is 47.7 mm (1.878 in.) and (38) Coat thrust bearing and race assembly with
inside diameter is 32.6 mm (1.283 in.). petroleum jelly and install it on clutch shaft. Bearing
• Race outer diameter is 53.6 mm (2.110 in.) and in faces up and toward case front as shown (Fig. 31).
side diameter is 30.6 mm (1.205 in.). Verify bearing/race size. Bearing and race outer di
(36) Rotate front of transmission case downward ameter is 47.8 mm (1.882 in.) and inside diameter is
and install assembled planetary gear/forward-direct 33.6 mm (1.301 in.).
clutch (Fig. 29).
BEARING A N D
RACE ASSEMBLY
J8921-698
Fig. 31 Installing Clutch Shaft Thrust Bearing And

Race Assembly
(39) Assemble second coast brake piston compo
nents (Fig. 32).
Fig. 29 Installing Front Planetary And Forward-
Direct Clutch Assembly PISTON
(37) Check clearance between sun gear input drum

and direct clutch drum (Fig. 30). Clearance should be
9.8 - 11.8 mm (0.386 - 0.465 in.). If clearance is in
correct, planetary gear/forward-direct clutch assem
bly is not seated or is improperly assembled. Remove,
and correct if necessary.
J8921-699
Fig. 32 Assembling Second Coast Brake Piston

(40) Install assembled second coast brake piston in
case.
(41) Install replacement seals on second coast
brake piston cover and install cover in case.
(42) Install second coast brake piston snap ring
with snap ring plier tool (Fig. 33).
(43) Check second coast brake piston stroke as fol
J8921-697 lows:
(a) Make reference mark on brake piston rod
Fig. 30 Checking Input Drum-To-Direct Clutch Drum (Fig. 34).
Clearance
4 AW-4 TRANSMISSION OVERHAUL 21 - 255
PISTON
PISTON ROD
SNAP REFERENCE
RING MARK
GAUGE
TOOL
J8921-700
Fig. 33 Installing Second Coast Brake Piston Snap

Ring
(b) Apply 57-114 psi air pressure through feed
hole (Fig. 34). Alternately apply and release air
J8921-702
pressure to operate piston.
(c) Check stroke with gauge 7552 (Fig. 35). Fig. 35 Checking Second Coast Brake Piston Stroke
(d) If stroke length is incorrect, piston, cover or
snap ring is not seated. Reassemble and check
stroke again if necessary. THRUST
~ RACE
BRAKE
PISTON R O D
TABBED T H R U S T W A S H E R
PISTON
FEED HOLE
OVERDRIVE
SUPPORT
J8921-701 J8921-703
Fig. 34 Marking Brake Piston Rod Fig. 36 Installing Overdrive Support Thrust Race
And Washer
(44) Coat thrust race and tabbed washer with pe
troleum jelly and install them on overdrive support (46) Install overdrive support snap ring with Snap
(Fig. 36). Verify race size. Race outer diameter is Ring Plier Tool 7540 (Fig. 38). Chamfered side of
50.9 mm (2.004 in.) and inside diameter is 36.2 mm snap ring faces up and toward case front. Snap ring
(1.426 in.). ends must be aligned with case opening with
(45) Install overdrive support in case. Use two long ring ends approximately 24 mm (0.94 in.) from
bolts to help align and guide support into position centerline of case opening.
(Fig. 37). (47) Install and tighten overdrive support bolts to
25 N*m (19 ft-lbs) torque (Fig. 39).
USE L O N G OVERDRIVE
BOLTS SUPPORT
T O INSTALL BOLTS
SUPPORT
OVERDRIVE
SUPPORT J8921-704 J8921-706
Fig. 37 Installing Overdrive Support Fig. 39 Installing Overdrive Support Bolts

DIAL
S N A P RING E N D S
CENTERED I N INDICATOR
S N A P RING T O O L
CASE O P E N I N G
Wfffr J8921-707
Fig. 40 Checking Output Shaft End Play

24 mm 0.94 in.)
OVERDRIVE
CLUTCH
FRONT S N A P RING PACK
K U N
^ ^ ^ ^ A M F E R
SNAP
RING
J8921-705
Fig. 38 Installing Overdrive Support Snap Ring

(48) Check output shaft end play with dial indica
tor (Fig. 40). End play should be 0.27 - 0.86 mm
(0.0106 - 0.0339 in.).
(49) If output shaft end play is incorrect, one or
more of installed components is not seated. Reassem
ble as necessary and check end play again.
J8921-708
(50) Install overdrive clutch pack (Fig. 41). Install
thickest clutch plate first. Rounded edge of plate Fig. 41 Install Overdrive Clutch Pack
faces up. Install first disc followed by another plate
until correct number of discs-plates are installed. In (51) Install stepped ring retainer plate with flat
stall four discs and three plates. side facing disc. Then install brake pack snap ring
(Fig. 42).
J
DIAL
INDICATOR
BRAKE
OVERDRIVE PISTON
CLUTCH PACK FEED
S N A P RING HOLE
J8921-711
Fig. 44 Checking Overdrive Brake Piston Stroke

J8921-709
(54) Remove overdrive brake piston snap ring and
Fig. 42 installing Overdrive Brake Snap Ring remove overdrive clutch pack components.
(55) Coat overdrive lower race, thrust bearing and
(52) Check overdrive brake piston stroke as fol upper race with petroleum jelly and install them in
lows: overdrive support (Fig. 45). Be sure races and bear
(a) Mount Gauge 7546 in dial indicator and posi ing are assembled and installed as shown.
tion gauge tool against overdrive brake piston (Fig. (56) Verify bearing/race sizes before proceeding.
43). Bearing-race sizes are:
• Outer diameter of lower race is 47.8 mm (1.882
in.) and inside diameter is 34.3 mm (1.350 in.).
• Outer diameter of bearing is 47.7 mm (1.878 in.)
GAUGE • Outer diameter of upper race is 47.8 mm (1.882
TOOL
in.) and inside diameter is 30.7 mm (1.209 in.).
J8921-710
Fig. 43 Positioning Gauge Tool And Dial Indicator

(b) Apply and release overdrive brake piston
with compressed air and note piston stroke length
on dial indicator. Apply air pressure through feed
hole in case (Fig. 44).
(c) Piston stroke length should be 1.40 - 1.70 mm
(0.55 - 0.66 in.).
J8921-712
(d) If stroke is incorrect, brake pack or piston is
installed incorrectly. Check and correct as neces
Fig. 45 Installing Overdrive Support Thrust Bearing
sary and measure piston stroke again.
And Races
(53) Remove dial indicator and gauge tool.
(57) Install overdrive planetary ring gear in sup and install it on planetary gear (Fig. 48). Race outer
port (Fig. 46). diameter is 41.8 mm (1.646 in.) and inside diameter
OVERDRIVE
is 27.1 mm (1.067 in.).
PLANETARY
RING OVERDRIVE
THRUST PLANETARY
RACE
(TABBED)
J8921-715
Fig. 48 Installing Planetary thrust Race

(61) Install assembled overdrive planetary gear
J8921-713 and clutch (Fig. 49).
Fig. 46 Installing Overdrive Planetary Ring Gear OVERDRIVE

PLANETARY
(58) Coat ring gear thrust race and thrust bearing AND
assembly with petroleum jelly and install them in CLUTCH
ASSEMBLY
gear (Fig. 47).
(59) Verify bearing/race size before proceeding.
• Outer diameter of ring gear race-bearing is 47.8
mm (1.882 in.) and inside diameter is 24.2 mm (0.953
in.).
• Outer diameter of bearing is 46.8 mm (1.844 in.)
T H R U S T BEARING
RACE ASSEMBLY
J8921-716
Fig. 49 Installing Overdrive Planetary And Clutch

Assembly
OVERDRIVE
PLANETARY (62) Coat thrust bearing and race assembly with
W RING GEAR petroleum jelly and install it on clutch input shaft
(Fig. 50). Bearing and race outer diameter is 50.2
mm (1.976 in.) and inside diameter is 28.9 mm (1.138
in.).
(63) Install overdrive brake pack as follows:
J8921-714
(a) Install 4.0 mm (0.157 in.) thick plate first.
Fig. 47 Installing Ring Gear Thrust Bearing And Rounded edge of plate must face upward.
Race (b) Install a disc followed by a plate until the re
quired number of discs and plates are installed. Be
(60) Coat tabbed thrust race with petroleum jelly
THRUST
BEARING
A N D RACE
ASSEMBLY
Fig. 50 Installing Input Shaft Thrust Bearing And Fig. 52 Installing Clutch Pack Snap Ring
Race Assembly
OIL PUMP
sure to install the stepped plate last with the flat
side of the plate facing the disc (Fig. 51).
(c) Confirm that four discs and three plates have
been installed.
OVERDRIVE
J8921-720
Fig. 53 Installing Oil Pump Thrust Race

J8921-718 CAUTION: Do not use force to seat the pump. T h e
seal rings on the stator shaft could be damaged if
Fig. 51 Installing Overdrive Clutch Pack they bind or stick to the direct clutch drum.
(64) Install clutch pack snap ring (Fig. 52).
(68) Tighten oil pump bolts to 22 N*m (16 ft. lbs.)
(65) Coat thrust bearing race with petroleum jelly
torque.
and install it in oil pump (Fig. 53). Bearing race
(69) Verify input shaft rotation. Shaft should ro
outer diameter is 47.2 mm (1.858 in.) and inside di
tate smoothly and not bind.
ameter is 28.1 mm (1.106 in.).
(70) Lubricate and install new O-ring on transmis
(66) Lubricate and install replacement O-ring on
sion throttle cable adapter and install cable in case
oil pump body.
(Fig. 55).
(67) Install oil pump in case. Align pump and case
(71) Check clutch and brake operation. Operate
bolt holes and carefully ease pump into place (Fig.
clutches and brakes with compressed air applied
54).
through feed holes in case (Fig. 56). Listen for clutch
PULLER
4 5 6
1 . OVERDRIVE DIRECT CLUTCH FEED

PUMP J8921-481 2. DIRECT CLUTCH FEED
3. FORWARD CLUTCH FEED
4. OVERDRIVE BRAKE FEED
Fig. 54 Installing Oil Pump 5. S E C O N D COAST BRAKE FEED
6. SECOND BRAKE FEED
7. FIRST-REVERSE BRAKE FEED _ _ ^ . T U i r
8. OVERDRIVE CLUTCH ACCUMULATOR PISTON H O L E (BLOCK T H I S

H O L E W H E N CHECKING DIRECT CLUTCH OPERATION)
J8921-721
Fig. 56 Clutch And Brake Feed Hole Locations
@ S E C O N D BRAKE ACCUMULATOR PISTON

(D DIRECT CLUTCH A C C U M U L A T O R PISTON
© OVERDRIVE BRAKE ACCUMULATOR PISTON
© OVERDRIVE CLUTCH ACCUMULATOR PISTON
THROTTLE
Fig. 55 Installing Transmission Throttle Cable

and brake application. If you do not hear a clutch or
brake apply, disassemble transmission and repair
fault before proceeding. It is necessary to block the
overdrive clutch accumulator feed hole No. 8
(Fig. 56) in order to check direct clutch opera
tion.
(72) Lubricate and install new O-rings on accumu
lator pistons (Fig. 57).
(73) Assemble and install accumulator pistons and
springs (Fig. 57).
(74) Install new check ball body and spring (Fig.
58).
(75) Position valve body on case (Fig. 59).
(76) Install detent spring (Fig. 59).
(77) Align manual valve, detent spring and shift
sector (Fig. 59). Fig. 57 Accumulator Piston And Spring Installation
J — AW-4 TRANSMISSION OVERHAUL 21 - 261
CHECK BALL THROTTLE

BODY A N D SPRING
J8921-725
Fig. 60 Connecting Transmission Throttle Cable

J8921-723
(80) Connect valve body solenoid wires to solenoids
Fig. 58 Installing Check Ball Body And Spring (Fig. 61).
SOLENOID W I R E
CONNECTORS
MANUAL
VALVE
J8921-724
J8921-433
Fig. 59 Aligning Manual Valve, Shift Sector And Fig. 61 Connecting Valve Body Solenoid Wires
Detent Spring
(81) Install new O-ring on solenoid harness
(78) Connect transmission throttle cable to throttle adapter and secure adapter to case.
valve cam (Fig. 60). (82) Install valve body oil tubes (Fig. 62). Tap
(79) Install and tighten valve body-to-case bolts to tubes into place with a plastic mallet. Be sure the
10 N*m (7 ft. lbs.) torque. flanged tube ends and straight tube ends are in
stalled as shown.
(83) Install new gaskets on oil screen and install
#
screen on valve body. Tighten screen bolts to 10 N m
(87) Install spacer and speedometer drive gear on

output shaft. Then install retaining snap ring (Fig.
64).
SPEEDOMETER
J8921-443
SPACER J8921-727
Fig. 62 Installing Valve Body Oil Tubes
Fig. 64 Installing Spacer And Speedometer Drive
(84) Install magnet in oil pan. Be sure magnet Gear
does not interfere with valve body oil tubes.
(85) Apply Mopar or Loctite 599 to sealing surface (88) Apply bead of Mopar or Loctite 599 sealer to
sealing surface at rear of case (Fig. 65).
of oil pan. Sealer bead should be at least 3 mm (1/8
in.) wide. Install pan on case and tighten pan bolts to
7 N*m (65 in. lbs.) torque.
(86) Install transmission speed sensor rotor and
key on output shaft (Fig. 63).
ROTOR
KEY
J8921-728
Fig. 65 Applying Sealer To Case Rear Flange

(89) Install adapter housing on transmission.
J8921-726 Tighten adapter bolts to 34 N»m (25 ft. lbs.) torque.
(90) Install transmission speed sensor (Fig. 66).
Fig. 63 Installing Transmission Speed Sensor Rotor
Tighten sensor bolt to 7.4 N»m (65 in. lbs.) torque
And Key
and connect sensor wire harness connector.
— AW-4 TRANSMISSION OVERHAUL 21 - 263
J (96) Align park/neutral position switch standard
line with groove or flat on manual shaft (Fig. 68).
(97) Tighten park/neutral position switch adjusting
bolt to 13 N*m (9 ft. lbs.) torque.
Fig. 66 Installing Transmission Speed Sensor

(91) Install converter housing (Fig. 67). Tighten 12
mm diameter housing bolts to 57 N*m (42 ft. lbs.)
torque. Tighten 10 mm diameter housing bolts to 34
J8921-431
Fig. 68 Park/Neutral Position Switch Installation/

Adjustment
(98) Install transmission shift lever on manual
valve shaft. Tighten lever attaching nut to 16 N»m
(99) Install retaining clamp for wire harness and
throttle cable (Fig. 69).
(100) Install torque converter.
(101) Verify that converter is seated by measuring
distance between converter housing flange and one of
Fig. 67 Installing Converter Housing

(92) Install transmission shift lever on manual
valve shaft. Do not install lever attaching nut at this
time.
(93) Move transmission shift lever fully rearward.
Then move lever two detent positions forward.
(94) Mount park/neutral position switch on manual
valve shaft and tighten switch adjusting bolt just
enough to keep switch from moving (Fig. 68).
(95) Install park/neutral position switch tabbed THROTTLE
CABLE
washer and retaining nut (Fig. 68). Tighten nut to J8921-732
6.9 N»m (61 in. lbs.) torque, but do not bend any of
the washer tabs against the nut at this time. Fig. 69 Installing Cable/Harness Clamps
21 - 264 AW-4 TRANSMISSION OVERHAUL 4
the converter mounting pads (Fig. 70). Use straight CONVERTER

edge and vernier calipers to measure distance. On M O U N T I N G PAD
6-cyl. transmissions, distance should be 16.5 mm

(0.650 in.).
(102) Secure converter in transmission with
C-clamp or metal strapping. Do this before mounting
transmission on jack or moving transmission under
vehicle.
(103) Install lower half of transmission fill tube (in
stall upper half after transmission is in vehicle).
CAUTION: The transmission cooler and lines

must b e r e v e r s e flushed i f overhaul corrected a
malfunction that g e n e r a t e d s l u d g e , metal particles,
or clutch friction material. The torque converter
should also be replaced if c o n t a m i n a t e d b y the
s a m e malfunction. D e b r i s and r e s i d u e not flushed
from t h e c o o l e r and l i n e s will f l o w b a c k into t h e
t r a n s m i s s i o n and c o n v e r t e r . T h e result will b e a re J8921-733
peat failure and s h o p c o m e b a c k .

Fig. 70 Checking Converter installation
J NP231 TRANSFER CASE 21 - 265
N P 2 3 1 TRANSFER CASE
INDEX
page page
General Information 265 Transfer Case Identification 266
Shift Linkage Adjustment 268 Transfer Case Installation . 269
Transfer Case Assembly 276 Transfer Case Lubricant 266
Transfer Case Disassembly and Overhaul 270 Transfer Case Removal 269
GENERAL INFORMATION Two versions of the NP231 are used. One version
The NP231 is a part-time transfer case with a low retains the synchronizer components used in previous
range reduction gear system (Fig. 1). The NP231 has models. A newly introduced version is not equipped
three operating ranges plus a Neutral position. A low with synchro components.
range system provides a reduction ratio for increased
low speed torque capability. The NP231 is used in XJ OPERATING RANGES
and YJ models. NP231 operating ranges are: 2-wheel drive high;
4-wheel drive high and 4-wheel drive low (Fig. 2).
Fig. 1 NP231 Transfer Case

21 - 288 NP231 TRANSFER CASE J
The NP231 is a part-time transfer ease. The

4-wheel drive ranges are undifferentiated and should
only be used on unpaved or low traction surfaces
only.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever. The shift lever is connected to the trans
fer case range lever by an adjustable linkage rod. A
straight line shift pattern is used (Fig. 2). Range po
sitions are marked on the shifter bezel cover plate. A
front axle disconnect mechanism is only used on cer
tain models.
J9121-434
2H 2H
Fig. 3 Transfer Case identification Tag
TRANSFER CASE LUBRICANT
4H 4H Recommended Lubricant
Use Mopar ATF Plus, type 7176, or Dexron II au
N tomatic transmission fluid in the NP231 transfer
case.
Lubricant Capacity
41 4L
Approximate refill lubricant capacity is 1.54 liters
(3.25 pints) for YJ and 1.04 liters (2.2 pints) for XJ.
YJ XJ J9021-117
Fill Level
Fig. 2 NP231 Shift Pattern The correct fill level is to the bottom edge of the
TRANSFER CASE IDENTIFICATION fill plug hole. The vehicle must be level in order to
A circular ID tag is attached to the rear case of ensure an accurate fluid level check.
each NP231 transfer case (Fig. 3). The ID tag pro
vides the transfer case model number, assembly
number, serial number and low range ratio.
The transfer case serial number also represents the
date of build. For example, a serial number of
8-10-92 would represent August 10, 1992.
NP231 SERVICE DIAGNOSIS
I Condition Possible Cause Correction
TRANSFER CASE (1) Vehicle speed too great to permit shifting. (1) Stop vehicle and shift into desired range. O r
DIFFICULT T O SHIFT O R reduce speed to 3-4 km/h (2-3 mph) before
W I L L N O T SHIFT I N T O attempting to shift.
DESIRED RANGE
(2) If vehicle was operated for extended period in 4 H (2) Stop vehicle, shift transmission to Neutral, shift
mode on dry paved surface, driveline torque load transfer case to 2 H mode and operate vehicle in
may cause difficulty. 2 H on dry paved surfaces.
(3) Transfer case external shift linkage binding. (3) Lubricate, repair or replace linkage bushings or
tighten loose components as necessary.
(4) Insufficient or incorrect lubricant. (4) Drain and refill to edge of fill hole with
DEXRON II® or MOPAR-MERCON® Automatic
Transmission Fluid.
(5) Internal components binding, worn or damaged. (5) Disassemble unit and replace worn or damaged
components as necessary.
TRANSFER CASE NOISY (1) Insufficient or incorrect lubricant. (1) Drain and refill to edge of fill hole with
IN ALL DRIVE M O D E S DEXRON II® or MOPAR-MERCON® Automatic
Transmission Fluid. Check for leaks and repair if
necessary. N o t e : I f u n i t i s s t i l l n o i s y a f t e r
d r a i n a n d r e f i l l , d i s a s s e m b l y and
i n s p e c t i o n m a y b e r e q u i r e d t o locate
source o f noise.
NOISY IN - OR JUMPS (1) Transfer case not completely engaged in 4L (1) Stop vehicle, shift transfer case to Neutral, then
O U T O F - FOUR W H E E L position. shift back into 4 L position.
DRIVE L O W RANGE
(2) Shift linkage out of adjustment. (2) Adjust linkage.
(3) Shift linkage loose or binding. (3) Tighten, lubricate or repair linkage as necessary.
(4) Range fork damaged, inserts worn, or fork is (4) Disassemble unit and repair as necessary.
binding on shift rail.
(5) Disassemble and repair as necessary.
(5) Low range gear worn or damaged.
LUBRICANT LEAKING (1) Transfer case overfilled. (1) Drain to correct level.
FROM O U T P U T SHAFT
SEALS OR FROM V E N T (2) Vent closed or restricted. (2) Clear or replace vent if necessary.
(3) Output shaft seals damaged or installed (3) Replace seals. Be sure seal lip faces interior of
incorrectly. case when installed. Also be sure yoke seal
surfaces are not scored or nicked. Remove scores
and nicks with fine sandpaper or replace yoke(s)
if necessary.
ABNORMAL TIRE W E A R (1) Extended operation on dry hard surface (paved) (1) Operate in 2 H on hard surface (paved) roads.
roads in 4 H range.
J9021-118
21 - 268 NP231 TRANSFER CASE
J
SHIFT LINKAGE ADJUSTMENT
LINKAGE ADJUSTMENT— YJ
(1) Remove transfer case shift knob locknut and
remove knob (Fig. 4).
(2) Remove outer boot attaching screws and re
move boot (Fig. 4).
(3) Remove inner boot attaching screws and re
move boot (Fig. 4).
(4) Move shift lever into 4L position.
Fig. 5 Installing Shift Lever Spacer— YJ
TRANSFER
CASE
SHIFT
LEVER J9121-439
Fig. 4 Transfer Case Shift Lever And Boots—YJ

(5) Insert 3 mm (1/8 in.) spacer between shift lever J9121-430
and forward edge of shift lever gate (Fig. 5). Secure
lever and spacer in place with tape or wire. Fig. 6 Shift Trunnion Lock Bolt Position—YJ
(6) Secure shift lever and spacer with tape or wire.
(3) Insert 3 mm (1/8 in.) spacer between shift lever
(7) Raise vehicle.
(8) Loosen lock bolt on adjusting trunnion (Fig. 6).
lever and spacer in place with tape or wire.
Linkage rod should now slide freely in trunnion.
(9) Verify that range lever is in 4L position (Fig. (4) Raise vehicle.
6). (5) Loosen trunnion lock bolt (Figs. 8 and 9). Link
(10) Position linkage rod so it is a free fit in range age rod should now slide freely in trunnion.
lever. Then tighten trunnion lock bolt (Fig. 6). (6) Verify that transfer case range lever is in 4L
(11) Lower vehicle. position.
(12) Remove shift lever spacer and install inner (7) Position linkage rod so it is a free fit in range
and outer boots and shift knob (Fig. 4). lever (Figs. 8 and 9). Then tighten trunnion locknut.
(8) Lower vehicle.
LINKAGE ADJUSTMENT—XJ (9) Remove shift lever spacer and install bezel.
(1) Remove shift lever bezel.
Fig. 7 Installing Shift Lever Spacer—XJ

SHIFT
BRACKET
BRACKET J9121-428
Fig. 9 Shift Linkage—XJ

(9) Disconnect transfer case linkage rod from
range lever.
(10) Disconnect transfer case vent hose.
(11) Support transfer case with transmission jack.
(12) Remove nuts attaching transfer case to trans
mission.
(13) Secure transfer case to jack with chains.
(14) Pull transfer case and jack rearward to disen
gage transfer case.
(15) Remove transfer case from under vehicle.
TRANSFER CASE INSTALLATION

(1) Mount transfer case on a transmission jack. Se
cure transfer case to jack with chains.
J9121-429
(2) Position transfer case under vehicle.
Fig. 8 Shift Linkage-YJ (3) Align transfer case and transmission shafts and
install transfer case on transmission.
TRANSFER CASE REMOVAL (4) Install and tighten transfer case attaching nuts
(1) Shift transfer case into Neutral. to 35 N«m (26 ft. lbs.) torque.
(2) Raise vehicle. (5) Connect vehicle speed sensor wires, and vent
(3) Drain transfer case lubricant. hose.
(4) Mark front and rear propeller shaft yokes for (6) Align and connect propeller shafts. Tighten
alignment reference. shaft attaching bolts to 19 N»m (170 in. lbs.) torque.
(5) Support transmission with jack stand. (7) Fill transfer case with Mopar ATF Plus, or
(6) Remove rear crossmember, or skid plate. Dexron II automatic transmission fluid.
(7) Disconnect front/rear propeller shafts at trans (8) Install rear crossmember, or skid plate. Tighten
fer case. crossmember bolts to 41 Nrni (30 ft. lbs.) torque.
(9) Remove transmission jack and transmission

support stand.
(10) Connect transfer case range lever to linkage
rod.
(11) Adjust transfer case shift linkage.
(12) Lower vehicle.
TRANSFER CASE DISASSEMBLY AND OVERHAUL

Two versions of the NP231 are used in current
models. One version retains the synchronizer
components used in previous years. A newly in
troduced version does not have synchro compo
nents. The non-synchro version does not have a
synchro gear, struts, spring and stop ring. Dur
ing overhaul, note which version is being ser
viced and order needed parts accordingly. Fig. 2 Rear Bearing Snap Ring Removal
(1) Remove fill and drain plugs.
(2) Remove front yoke. Discard yoke seal washer CAUTION: Do not pry against the sealing surfaces
and nut. They should not be reused. of the retainer or rear case. The surfaces could be
(3) Move transfer case range lever rearward to 4L damaged.
position.
(4) Remove extension housing attaching bolts.
(5) Tap extension housing in clockwise direction to
break sealer bead and remove housing (Fig. 1).
CAUTION: To avoid damaging the sealing sur

faces of the extension housing and rear retainer, do
not pry or wedge the housing off the retainer.
Fig. 3 Rear Retainer Removal

(9) Remove bolts attaching rear case to front case.
Retain bolts and washers.
(10) Separate rear case from front case (Fig. 4) In
sert screwdrivers into slots cast in case ends. Then
gently pry upward to break sealer bead and loosen
rear case.
Fig. 1 Extension Housing Removal

(6) Remove rear bearing snap ring (Fig. 2).
(7) Remove rear retainer attaching bolts.
(8) Remove rear retainer. Position screwdriver un
der each tab on retainer housing (Fig. 3). Then care
fully pry retainer upward and off rear case.
CAUTION; Do not pry against the sealing surfaces

of the retainer or rear case. T h e surfaces could b e
damaged.
TUBE P I C K U P SCREEN RR21F26
Fig, 6 Removing Oil Screen And Pickup Tube 16

(14) Remove oil pump from rear case.
(15) Remove pickup tube O-ring from oil pump
Fig, 4 Loosening Rear Case (Fig. 7).
(11) Remove oil pump and rear case as an assem OIL P U M P
bly (Fig. 5).
OIL
PUMP
O-RING RR21F27
Fig, 7 Pickup Tube O-Ring Location

(16) The oil pump can be disassembled for
cleaning and inspection as described in steps
(17) and (18). However, the pump parts are NOT
serviceable separately. If any pump component
is worn, or damaged, the pump must be re
placed as an assembly.
(17) If oil pump will be disassembled for inspec
tion, mark position of oil pump housings for refer
ence (Fig. 8). Remove screws that attach two halves
of the pump. Then remove feed housing from gear
housing (Fig. 8).
(18) Mark position of pump gears and remove
them from housing (Fig. 8).
Fig, 5 Rear Case And Oil Pump Removal (19) Remove mode spring (Fig. 9).
(20) Tap front output shaft upward with a rawhide
(12) Slide oil screen out of case pocket. Disconnect mallet to free it from shaft bearing.
screen from pickup tube and remove screen (Fig. 6). (21) Remove front output shaft and drive chain as
(13) Remove pickup tube from oil pump (Fig. 6). assembly (Fig. 10).
GEAR FEED (22) Remove mainshaft, mode fork and shift rail as
HOUSING HOUSING
assembly (Fig. 11).
SHIFT RAIL MAINSHAFT
ASSEMBLY
MODE
FORK
RR21F31
PUMP Fig. 11 Removing Mainshaft, Mode Fork And Shift
GEARS
Rail
J8921-195
(23) Remove mode fork and shift rail from synchro
Fig. 8 Oil Pump Components sleeve (Fig. 12).
RR21F29
Fig. 9 Mode Spring Removal

FRONT OUTPUT
SHAFT
J8921-199
Fig. 12 Removing Mode Fork From Sleeve
RR21F30
Fig. 10 Front Output Shaft And Drive Chain
Removal
NP231 TRANSFER CASE 21 - 273
(24) Remove synchro hub snap ring (Fig. 13). (27) Remove drive sprocket (Fig. 16).
SYNCHRONIZER
ASSEMBLY
DRIVE
MAINSHAFT
SPROCKET
S T R U T (3)
MAINSHAFT
SNAP
RING
RP1114 J9021-5
Fig. 13 Synchro Hub Snap Ring Fig. 16 Drive Sprocket Removal/Installation

Removal/installation (28) Slide range fork pin out of shift sector (Fig.
(25) Remove synchro sleeve, hub and struts (Fig. 17).
14).
SHIFT
SECTOR
SYNCHRONIZER
SLEEVE A N D H U B
J9121-438
DRIVE
SPROCKET MAINSHAFT J9221-79
Fig. 17 Disengaging Range Fork
Fig. 14 Removing Synchro Sleeve, Hub And Struts (29) Remove range fork and shift hub (Fig. 1 8 ) .
(26) Remove synchro hub and stop ring (Fig. 15).
SYNCHRO
HUB
MAINSHAFT
STOP
RING
, RANGE FORK
DRIVE fl^j A N D SHIFT H U B
SPROCKET J9121-427
J902M
Fig. 18 Range Fork And Hub Removal/Installation
Fig. 15 Removing Synchro Hub And Stop Ring
(30) Remove range lever from sector shaft.

(31) Remove shift sector (Fig. 19).
SHIFT
SECTOR
J9121-426
J9Q21-8 Fig. 21 Detent Component Removal

FRONT
Fig. 19 Shift Sector Removal/installation CASE FRONT
BEARING
(32) Remove sector shaft bushing and O-ring (Fig. RETAINER
20).
. ^ ^ ^
J902M1
Fig. 22 Front Bearing Retainer Bolt Locations

(35) Remove front bearing retainer. Position screw
J9021-9
drivers in retainer slots and lift upward to loosen
and remove retainer (Fig. 23).
Fig. 20 Removing/Installing Sector Shaft Bushing INPUT GEAR
And O-Ring BEARING
RETAINER
(33) Remove shift detent plunger, spring and plug
(Fig. 21). Remove O-ring from plug after removal.
(34) Turn front case over and remove front bearing
retainer bolts (Fig. 22).
POSITION
SCREWDRIVER
IN RETAINER mm^mmwmM*
J902M2
SLOTS WHW
Fig. 23 Removing Front Bearing Retainer

(36) Remove input gear snap ring (Fig. 24). (39) Remove retainer, thrust washers and input
gear from low range gear (Fig. 27).
Fig. 24 Removing input Gear Snap Ring

(37) Press input and low range gear assembly out Fig. 27 Input And Low Range Gear Components
of input gear bearing with shop press (Fig. 25). (40) Remove oil seals from rear retainer, rear ex
tension housing, oil pump feed housing and case
halves.
(41) Remove magnet from front case.
(42) Remove the speedometer driven gear, seals
and adapter.

Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
case and retainer seal surfaces.
Clean the oil pickup screen with solvent and dry it
with compressed air. Also use compressed air to re
move solvent residue from all oil feed passages and
channels.
Inspect the low range annulus gear (Fig. 28). If the
gear is damaged, replace the gear and front case
Fig. 25 Removing Input And Low Range Gear as an assembly. Do not attempt to remove the
Assembly gear.
(38) Remove low range gear snap ring (Fig. 26).
Fig. 28 Low Range Annulus Gear Location

Fig. 26 Removing Low Range Gear Snap Ring
21 - 2 7 1 NP231 TRANSFER CASE J
Inspect the case halves, extension housing and re

tainers for cracks, porosity, or damaged sealing sur
faces. Inspect the shafts, gears, chain and shift
components for wear or damage. Replace the oil
pump as an assembly if any pump part is worn or
damaged.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam
aged bearings as outlined in the assembly section.
TRANSFER CASE ASSEMBLY
CAUTION; The bearing bores in various transfer

case components contain oil feed holes. Be sure re
placement bearings do not block these feed holes.
(1) Lubricate components with automatic transmis

sion fluid (or petroleum jelly where indicated) during Fig. 30 Installing Output Shaft Front Bearing
assembly. (9) Carefully press input gear bearing into case
(2) Remove front output shaft seal from front case. until bearing snap ring seats against case (Fig. 32).
(3) Remove front output shaft bearing snap ring
SPECIAL T O O L SPECIAL T O O L
(Fig. 29).
Fig. 31 Removing Input Gear Bearing

SEAT FRONT
BEARING CASE
Fig. 29 Removing/installing Front Output Shaft

Bearing Snap Ring
(4) Tap old front output shaft bearing out of front
case with plastic mallet. Install new bearing with
Tool Handle C-4171 and Installer Tool 5064 (Fig. 30).
(5) Secure front output shaft bearing in front case
with new snap ring (Fig. 29).
(6) Install new front output shaft seal in front
case.
(7) Press input gear bearing from the front case
with Tool Handle C-4171 and Installer Tool C-4210
(Fig. 31). Then turn front case over.
(8) Install snap ring on new input gear bearing Fig. 32 Input Gear Bearing Installation
and start bearing in case.
(10) Remove mainshaft pilot bearing from input THRUST

gear with Tool MD-998346 and two suitable size WASHERS
open end wrenches (Fig. 33).

WRENCH SPECIAL T O O L
MD-998346
L O W RANGE
GEAR
INPUT
GEAR
^RETAINER J9021-15
WRENCH I N P U T GEAR
Fig. 35 Input And Low Range Gear Assembly
RP1112 the end surfaces of the low range gear. The gear
case and thrust washers could be damaged.
Fig. 33 Removing Mainshaft Pilot Bearing From DO NOT ALLOW
D O N O T PRESS
Input Gear AGAINST T H E S E PRESS T O O L T O
SURFACES O F BEAR AGAINST
(11) Install new pilot bearing in input gear with L O W RANGE GEAR PILOT BEARING
shop press, Tool Handle C-4171 and Installer 5065
(Fig. 34).
SPECIAL T O O L ARBOR PRESS RAM
HANDLE C-4171
SPECIAL T O O L
5065
ÔJ9Q21-18
Fig. 36 Input And Low Range Gear Installation

(17) Install input gear snap ring (Fig. 37).
S N A P RING f ^ f I N P U T GEAR
RP1113 PLIERS
I N P U T GEAR
Fig. 34 Installing Mainshaft Pilot Bearing In Input

Gear
(12) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig.
35).
(13) Install input gear snap ring (Fig. 36).
(14) Lubricate input gear with automatic transmis
sion fluid.
(15) Start input gear in front bearing.
(16) Press input gear into front bearing (Fig. 36).
S N A P RING RR21F53
CAUTION: Use a proper size tool to press the in
put gear into the front bearing. An incorrect tool Fig. 37 Installing Input Gear Snap Ring
could push the input gear pilot bearing too far into
(18) Install new oil seal in front bearing retainer.
the gear bore (Fig. 45). Also, do not press against
(19) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket aker, silicone sealer, or Loctite 518 to front bear

ing retainer seal surface (Fig. 38).
(20) Install front bearing retainer on front case
(Fig. 22). Tighten retainer bolts to 21 N*m (16 ft.
lbs.) torque.
Fig. 38 Applying Sealer To Front Bearing Retainer

(21) Install new sector shaft O-ring and bushing
(Fig. 39).
Fig. 41 Installing Detent Plunger, Spring And Plug

(25) Inspect range fork pads (Fig. 42). Be sure pads
are secure and in position.
RANGE
Fig. 39 Installing Sector O-Ring And Bushing

(22) Install shift sector in the case (Fig. 40).
(23) Install range lever and lever attaching nut on
shift sector. Tighten attaching nut to 30 N T T I (22 ft.
lbs.) torque.
J9121-431
Fig. 42 Range Fork Pads

(26) Assemble range fork and shift hub (Fig, 43).

(27) Engage range fork pin in sector slot (Fig. 44).
(28) If drive sprocket bearings are to be replaced,
Fig. 45 Removing Drive Sprocket Bearings
Fig. 43 Assembling Range Fork And Shift Hub

SHIFT
Fig. 44 Seating Range Fork In Sector

remove and install them as follows:
(a) Press both bearings out of sprocket simulta
neously with Remover Tool C-4667, or 5066 and
Tool Handle C-4171 (Fig. 45).
(b) Before installing new bearings, refer to Fig
ure 46 and note correct bearing position in
sprocket. Bearings must be also be installed in
proper sequence. Install front bearing first and rear
bearing last.
RR21F32
CAUTION: Do not press the bearings any farther

into the sprocket than indicated in Figure 46. The Fig. 46 Correct Position Of Bearings In Sprocket
bearings could block the mainshaft oil feed hole if
pressed too deeply into the sprocket. (29) Install spring and three struts in synchro hub
(Fig. 49).
(c) Install new front bearing first. Press bearing (30) Lubricate drive sprocket bearings, stop ring
flush with edge of sprocket bore (Fig. 47). and synchro hub with automatic transmission fluid.
(d) Install new rear bearing (Fig. 48). Press
bearing in until 4.6 mm (3/16 in.) below edge of
bore as shown in Figure 46.
21 - 280 NP231 T R A l S F E i CASE J
- A R B O R P R E S S RAM (31) Install sprocket, stop ring and synchro hub on

mainshaft (Fig. 50). Be sure to seat hub struts on
stop ring lugs.
SYNCHRO
SPECIAL T O O L HUB
HANDLE G4171
SPECIAL T O O L
5061 STOP
DRIVE
(NOTE POSITION) RING
SPROCKET
RP1117
Fig. 47 Installing Drive Sprocket Front Bearing DRIVE

SPROCKET
" A R B O R P R E S S RAM
SPECIAL T O O L
"HANDLE C4171 J8921-232
Fig. 50 Drive Sprocket, Stop Ring And Synchro Hub

Installation
SPECIAL T O O L
5061 (32) Install new synchro hub snap ring (Fig. 51).
(NOTE POSITION)
DRIVE S N A P RING
"SPROCKET PLIERS
RP1118
Fig. 48 Installing Drive Sprocket Rear Bearing MAINSHAFT

SNAP
SYNCHRO RING
S T R U T S (3) SPRING HUB
SYNCHRO
HUB
J9021-24
Fig. 51 Installing Synchro Hub Snap Ring

(33) Install sleeve on synchro hub. Be sure sleeve
is installed with beveled spline ends facing stop ring.
(34) Install new pads on mode fork and install
f J9Q21-23 shift rail in fork.
(35) Engage mode fork in synchro sleeve (Fig. 52).
Fig. 49 Installing Synchro Hub Spring And Struts
(36) Install mode fork-mainshaft assembly in case

(Fig. 52). Be sure the mode fork rail is seated in both
range fork bushings.
Fig. 54 Installing Mode Spring

(b) Seat new bearing in rear case with Tool Han
dle C-4171 and Bearing Installer 5063 (Fig. 56).
Fig. 52 installing Mainshaft And Mode Fork
Assembly
(37) Assemble and install output shaft and drive
chain (Fig. 53). Lift mainshaft slightly to ease chain
and shaft installation.
Fig. 53 Drive Chain And Front Output Shaft

installation
(38) Install mode spring on shift rail (Fig. 54).
(39) If front output shaft rear bearing is to be re
placed, install new bearing as follows:
(a) Remove bearing from rear case with Bearing
Remover MD-998346 and two suitable size
wrenches (Fig. 55).
Fig. 56 installing Front Output Shaft Rear Bearing

(40) Install new seal in oil pump feed housing (Fig. OIL P U M P
57).
OIL PUMP
O-RING RR21F27
Fig. 59 Pickup Tube O-Ring Installation

(45) Install assembled oil pump, pickup tube and
Fig. 57 Installing Oil Pump Feed Housing Seal screen in rear case. Be sure screen is seated in case
slot as shown (Fig. 60).
(41) If new oil pump is being installed, proceed
to step (43). If original pump was only disassem
bled for cleaning and inspection, proceed to step
(42).
(42) Assemble oil pump. Lubricate and install two
gears in gear housing. Align and install feed housing
on gear housing (Fig. 58). Install and tighten oil
pump screws to 2 N»m (14 in. lbs.) torque.
GEAR FEED
HOUSING HOUSING
TUBE PICKUP SCREEN RR21F26
Fig. 60 Pickup Tube, Oil Screen And Pump

Installation
(46) Install magnet in front case.
(47) Apply 3 mm (1/8 in.) wide bead of Mopar gas
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of front case.
GEARS
J8921-195

(43) Install new pickup tube O-ring in oil pump
(Fig. 59).
(44) Insert oil pickup tube in oil pump. Then at
tach oil screen and connecting hose to pickup tube
(Fig. 60).
(48) Align and install rear case on front case (Fig. SPECIAL T O O L
61). Be sure case locating dowels are in place and HANDLE C 4 1 7 1
ARBOR PRESS RAM
that mainshaft splines are engaged in oil pump inner
gear.
SPECIAL T O O L
5064
REAR
RETAINER RP1129
Fig. 62 Installing Mainshaft Rear Bearing In Rear

Retainer
REAR SNAP RING
RETAINER
REAR
BEARING
J8921-192
Fig. 61 Installing Rear Case On Front Case RR21F22
(49) Install and tighten front case-to-rear case at Fig. 63 Installing Rear Bearing Snap Ring
taching bolts to 41 N*m (30 ft. lbs.) torque. Be sure
to install a washer under each bolt used at case (56) Install new extension housing bushing with
dowel locations. Installer Tools C-4171 and 5066 (Fig. 65).
(50) Install mainshaft rear bearing in rear retainer SPECIAL T O O L IftdF" ARBOR PRESS RAM
(Fig. 62). Tap old bearing out of retainer with ham H A N D L E C-4171
mer and brass drift. Then install new bearing with

Tool Handle C-4171 and Installer 5064.
flange surface of rear retainer.
(52) Install locating dowel in rear retainer and in SPECIAL T O O L
C4338-A
stall retainer on case. Tighten retainer bolts to 24
(53) Install new rear bearing snap ring (Fig. 63).
Lift mainshaft slightly to seat snap ring in shaft
groove.
(54) Remove extension housing seal if not removed EXTENSION
HOUSING RP1127
previously.
(55) Remove extension housing bushing with
Fig. 64 Removing Extension Housing Bushing
Bushing Installer Tools C-4171 and C-4338-A (Fig.
64). (57) Install new seal in extension housing.
SPECIAL T O O L ARBOR P R E S S RAM (63) Install vacuum switch in case. Tighten switch
HANDLE G4171 to 47 N«m (35 ft. lbs.) torque.
(64) Install speedometer pinion and adapter (Fig.
66).
SPEEDOMETER
PINION
ADAPTER
SPECIAL T O O L
O-RING
5066
SPEEDOMETER
ADAPTER
EXTENSION
HOUSING RP1128 SENSOR
ADAPTER
Fig. 65 Installing Extension Housing Bushing
(58) Apply 3 mm (1/8 in.) wide bead of Mopar gas ADAPTER
ket maker, silicone adhesive sealer, or Loctite 518 to CLAMP
mounting surface of extension housing.

SEAL
(59) Install extension housing on case and tighten RETAINER
housing bolts to 4 1 N»m (30 ft. lbs.) torque. RING
VEHICLE
(60) Install front yoke. Secure yoke with replace SPEED
ment seal washer and nut. Tighten nut to 149 N*m SENSOR
J9321-258
(61) Install replacement gasket on vacuum switch Fig. 66 Speedometer Components (YJ Shown)
and install switch in case. (65) Fill transfer case with Mopar ATF Plus or
(62) Install tighten drain plug to 47 N«m (35 ft. Dexron II automatic transmission fluid after installa
lbs.) torque. tion.
(66) Install and tighten fill plug to 4 1 N*m (35 ft.
lbs.) torque.
LEGEND FOR NP231 TRANSFER CASE
I . Front Yoke, Nut, Seal Washer, and Oil Seal 18. Synchro Sleeve* 3 5 . Rear Retainer
2 . Shift Detent Plug, Spring and Pin 19. Stop Ring* 3 6 . Extension Housing
3. Front Retainer and Seal 2 0 . Snap Ring 3 7 . Bushing
4 . Front Case 2 1 . Output Shaft Front Bearing 3 8 . O i l Seal
5 . Vacuum Switch and Seal 2 2 . Front Output Shaft 3 9 . O i l Pickup Screen
6 . Vent Assembly 2 3 . Drive Sprocket 4 0 . Tube Connector
7. Input Gear Bearing and Snap Ring 2 4 . Drive Chain 4 1 . O i l Pickup Tube
8. Low Range Gear Snap Ring 2 5 . Drive Sprocket Bearings 4 2 . Pickup Tube O- R in g
9 . Input Gear Retainer 2 6 . Output Shaft Rear Bearing 4 3 . Magnet
10. Low Range Gear Thrust W a s h e r s 2 7 . Mainshaft 4 4 . Range Lever N u t and W a s h e r
1 1 . Input Gear 2 8 . O i l Seal 4 5 . Range Lever
1 2 . Input Gear Pilot Bearing 2 9 . O i l Pump Assembly 4 6 . Sector O- R in g and Seal
13. Low Range Gear 3 0 . Mainshaft Rear Bearing 4 7 . Sector
14. Range Fork Shift Hub 3 1 . Snap Ring 4 8 . Mode Spring
1 5 . Synchro Hub Snap Ring* 3 2 . Rear Case 4 9 . Mode Fork
1 6 . Synchro Hub Springs* 3 3 . Fill Plug and Gasket 5 0 . Range Fork
1 7 . Synchro Hub and Struts* 3 4 . Drain Plug and Gasket
•Synchro equipped models only.

J9221-76
NP242 TRANSFER CASE
INDEX
page page
Cleaning and Inspection 299 Transfer Case Fill Level 288
General Information 287 Transfer Case Identification 288
Shift Linkage Adjustment 290 Transfer Case Installation 290
Transfer Case Assembly 300 Transfer Case Lubricant 288
Transfer Case Disassembly and Overhaul . . . . . 290 Transfer Case Removal 290
GENERAL INFORMATION Two-wheel drive and full-time 4-wheel drive ranges

The NP242 is a full and part time transfer case are for normal on-road, highway operation. The part-
with four operating ranges (Fig. 1). The NP242 pro time high and low ranges are for off road operation,
vides either 2-wheel drive or full time 4-wheel drive or when the vehicle is driven on surfaces covered by
operation. An interaxle differential is used to control snow, ice or similar low traction elements.
torque transfer to the front and rear axles. A low
range gear reduction system provides increased low SHIFT MECHANISM
speed torque capability. Transfer case operating ranges are selected with a
The differential has a locking mechanism for undif floor mounted shift lever. The shift lever is connected
ferentiated 4-wheel drive in high and low ranges. to the transfer case range lever by an adjustable
The vehicle should only be operated on low traction linkage rod. Range positions are marked on the
road surfaces with the differential locked. shifter bezel plate (Fig. 2).
J8921-243
Fig. 1 NP242 Transfer Case

OPERATING RANGES
\1 J9021-113
The NP242 transfer case operating ranges are: Fig. 2 NP242 Shift Pattern
2-wheel drive, part-time 4-wheel drive, full time
4-wheel drive and 4-wheel drive low.
The full time 4-wheel drive range is fully differen
tiated and can be used at any time.
The part time 4-wheel drive high and low ranges
are not differentiated. They are for off road use only.
The low range reduction gear system is operative
in 4-low range only. Low range reduction ratio is
2.72:1.
TRANSFER CASE IDENTIFICATION

A circular I.D. tag is attached to the rear case of
each NP242 transfer case (Fig. 3). The tag provides
the transfer case model number, assembly number,
serial number and low range ratio.
The transfer case serial number also represents the
date of build. For example, a serial number of 10-
5-91 would represent October 5, 1991.
TRANSFER CASE LUBRICANT

Recommended fluid for the NP242 transfer case is
Mopar ATF Plus, Type 7176, or Dexron II automatic
transmission fluid.
Lubricant capacity of the Model 242 transfer case
is: 1.4 liters (1.48 qts.).
Fig. 3 Transfer Case I.D. Tag
TRANSFER CASE FILL LEVEL
Correct fill level for the NP242 transfer case is to
the bottom edge of the fill plug hole.
NP242 SERVICE DIAGNOSIS
TRANSFER CASE (1) Transfer case external shift linkage binding. (1) Lubricate, repair or replace linkage, or tighten
DIFFICULT T O SHIFT OR loose components as necessary.
WILL N O T SHIFT INTO
DESIRED RANGE
(2) Insufficient or incorrect lubricant. (2) Drain and refill to edge of fill hole with DEXRON
II® or MOPAR-MERCON® Automatic
Transmission Fluid.
(3) Internal components binding, worn or damaged. (3) Disassemble unit and replace worn or damaged
components as necessary.
TRANSFER CASE NOISY (1) Insufficient or incorrect lubricant. (1) Drain and refill to edge of fill hole with DEXRON
IN ALL DRIVE POSITIONS II® or MOPAR-MERCON® Automatic
Transmission Fluid. Check for leaks and repair if
necessary N o t e : I f u n i t i s s t i l l n o i s y a f t e r
drain and refill, disassembly and
inspection m a y be r e q u i r e d t o locate
source of noise.
LUBRICANT LEAKING (1) Transfer case overfilled. (1) Drain to correct level.
FROM O U T P U T SHAFT
SEALS OR FROM VENT
(2) Vent closed or restricted. (2) Clear or replace vent if necessary.
(3) Output shaft seals damaged or installed (3) Replace seals. Be sure seal lip faces interior of
incorrectly. case when installed. Also be sure yoke seal
surfaces are not scored or nicked. Remove scores
and nicb with fine sandpaper or replace yoke(s)
if necessary.
T R A N S F E R CASE W I L L (1) Incomplete shift due to drivetrain (1) Driver must momentarily release the
NOT SHIFT THROUGH torque load. accelerator pedal to complete the shift.
4 X 4 PART-TIME
RANGE (2) Incorrect tire pressure(s). (2) Inflate all tires equally to correct pressure.
(Light Remains On).
(3) Excessive tire wear. (3) Switch tires — Install the t w o tires w i t h
the most wear (one on the f r o n t axle
(4) Excessive vehicle loading. and one on the rear axle).
(4) Check vehicle loading — Do not exceed

the vehicle's GVW.
J9121-435
SHIFT LINKAGE ADJUSTMENT

(1) Remove shift lever bezel.
(3) Insert 3 mm (1/8 in.) spacer between shift lever
lever and spacer in place with tape or wire.
Fig. 4 Installing Shift Lever Spacer

(4) Raise vehicle.
(5) Loosen trunnion lock bolt (Fig. 5). Linkage rod BRACKET J9121-428
should now slide freely in trunnion.
(6) Verify that transfer case range lever is in 4L Fig. 5 Transfer Case Shift Linkage
position. TRANSFER CASE INSTALLATION
(7) Position linkage rod so it is free fit in range le
(1) Mount transfer case on transmission jack. Se
ver (Fig. 5). Then tighten trunnion lock bolt.
cure transfer case to jack with safety chains.
(8) Lower vehicle.
(2) Position transfer case under vehicle.
(9) Remove shift lever spacer and install bezel.
(3) Align transfer case and transmission shafts and
TRANSFER CASE REMOVAL install transfer case on transmission.
(1) Shift transfer case into Neutral. (4) Install and tighten transfer case attaching nuts
(2) Raise vehicle. to 35 N*m (26 ft. lbs.) torque.
(3) Drain transfer case lubricant. (5) Connect speedometer cable, vent hoses and
(4) Mark front and rear propeller shaft yokes for electrical switch connector.
alignment reference. (6) Align and connect propeller shafts. Tighten
(5) Place support stand under transmission. shaft U-joint clamp bolts to 19 N»m (14 ft. lbs.)
(6) Remove rear crossmember. torque.
(7) Disconnect front/rear propeller shafts at trans (7) Fill transfer case with recommended automatic
fer case. transmission fluid.
(8) Disconnect vehicle speed sensor wires and re (8) Install rear crossmember. Tighten crossmember
move sensor and speedometer adapter. bolts to 41 N-m (30 ft. lbs.) torque.
(9) Disconnect transfer case shift rod from range (9) Remove transmission jack and transmission
lever. support stand.
(10) Disconnect transfer case vent hoses and elec (10) Connect transfer case range lever to shift rod.
trical switch connector. (11) Check and adjust transfer case shift linkage if
(11) Support transfer case with transmission jack. necessary.
(12) Remove bolts attaching the transfer case to (12) Lower vehicle.
transmission.
(13) Secure transfer case to jack with chains. TRANSFER CASE DISASSEMBLY AND OVERHAUL
(14) Pull transfer case and jack rearward to disen (1) Remove fill and drain plugs.
gage transfer case. (2) Remove front yoke. Discard yoke seal washer
(15) Remove transfer case from under vehicle. and nut.
(3) Move range lever rearward to 4L position. (7) Remove rear retainer attaching bolts.
(4) Remove extension housing attaching bolts. (8) Loosen rear retainer (Fig. 8). Position long
(5) Tap extension housing in a clockwise direction screwdriver under each tab at ends of retainer hous
to break sealer bead and remove housing (Fig. 6 ) . ing and pry retainer upward.
CAUTION: To avoid damaging the sealing surfaces CAUTION: Do not pry against the sealing surfaces
of the extension housing and rear retainer, do not of the retainer or rear case. The surfaces could b e
attempt to pry or wedge the housing off the re damaged.
tainer.
Fig. 6 Extension Housing Removal Fig. 8 Loosening Rear Retainer

(6) Remove rear bearing snap ring from mainshaft (9) Lift rear retainer up and off case and main-
(Fig. 7 ) . Discard snap ring. shaft (Fig. 9).
Fig. 7 Removing Rear Bearing Snap Ring Fig. 9 Remove Rear retainer
(10) Remove bolts attaching rear case to front case. (13) Slide oil screen (Fig. 12) out of case pocket.
Retain bolts and the washers. OIL P U M P
(11) Loosen rear case with two screwdrivers (Fig.
10). Insert screwdrivers into slots cast in case ends.
Then gently pry upward to break sealer bead.
CAUTION: Do not pry against the sealing surfaces

of the front case or rear case. T h e surfaces could
be damaged.
PICKUP T U B E
OIL
SCREEN
J8921-249
Fig. 12 Unseating Oil Screen

(14) Remove oil pump, pickup tube and oil screen
from rear case (Fig. 13).
OIL
PUMP
INSERT
SCREWDRIVER-
I N CASE
SLOTS
J8921-191
Fig. 10 Loosening Rear Case

(12) Remove rear case and oil pump as assembly OIL
SCREEN
(Fig. 11).
REAR
CASE
PICKUP
TUBE
J8921-250
Fig. 13 Removing Oil Pump, Tube And Screen
J8921-248
Fig. 11 Removing Rear Case And Oil Pump

J IP242 TRANSFER CASE 21 - 293
(15) Remove pickup tube and screen from pump. (Fig. 15). Then mark position of pump gears and re
(16) Remove pickup tube O-ring from oil pump move them from housing (Fig. 15).
(Fig. 14). (20) Remove magnet from front case.
(21) Remove drive sprocket snap ring (Fig. 16).
OIL
PUMP
DRIVE
SPROCKET
J892M94
Fig. 14 Removing Pickup Tube O-Ring

(17) Remove and discard oil pump seal.
(18) The oil pump can be disassembled for cleaning J8921-251
and inspection as described in step (19). However,
pump parts are not serviceable separately. If Fig. 16 Removing Drive Sprocket Snap Ring
any pump component is worn, or damaged, (22) Remove drive sprocket and chain (Fig. 17).
pump must be replaced as an assembly.
(19) If oil pump will be disassembled for inspec
tion, mark position of oil pump housings for refer
ence (Fig. 15). Remove screws that attach two halves
of the pump. Remove feed housing from gear housing
GEAR FEED
HOUSING HOUSING
J8921-252
fig. 17 Removing Drive Sprocket And Chain
PUMP
GEARS
J8921-195

(23) Remove front output shaft (Fig. 18). (27) Remove range fork lockpin with size number
one easy-out tool. Grip easy-out tool with locking pli
ers and remove pin with counterclockwise, twist and
pull motion (Fig. 20).
L O W RANGE FORK
LOCK PIN
J8921-253
EASY-OUT
Fig. 18 Removing Front Output Shaft
(24) Remove transfer case shift lever nut and le J8921-254
ver.
(25) Remove shift detent plug, spring and pin (Fig. Fig. 20 Removing Low Range Fork Lockpin
19) (28) Remove shift rail by pulling it straight up and
out of fork (Fig. 21).
SHIFT
RAIL
Fig. 19 Removing Detent Components

(26) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low
range fork lockpin with access hole (Fig. 20).
J8921-255
Fig. 21 Removing Shift Rail

(29) Remove mode fork and mainshaft as assembly (31) Remove intermediate clutch shaft snap ring
(Fig. 22). (Fig. 24).
(30) Remove mode shift sleeve and mode fork as- Ring
sembly from mainshaft (Fig. 23). Note position of ( 3 2 ) R e m o v e cl u t c h s h a f t t h r u s t r i n g ( F i g 2 5 )
mode sleeve in fork and remove sleeve.
J8921-257
Fig. 23 Removing Mode Fork And Sleeve

21 - 296 NP242 TRANSFER CASE ^ J
(33) Remove intermediate clutch shaft (Fig. 26). (35) Remove differential (Fig. 28).
(34) Remove differential snap ring (Fig. 27). Fig. 28 Differential Removal
Fig. 29 Disengage Low Range Fork

(38) Remove low range fork and hub (Fig. 30). (40) Remove shift sector bushing and O-ring (Fig.
32).
LOW
RANGE
FORK
J8921-264
// /
J8921-207
I
Fig. 30 Removing Low Range Fork And Hub F/gr. 32 Removing Sector Bushing And O-Ring
(39) Remove the shift sector (Fig. 31). (41) Remove front bearing retainer bolts.
(42) Remove front bearing retainer. Carefully pry
LOW retainer loose with screwdriver (Fig. 33). Position the
RANGE screwdriver in the slots cast into retainer.
SHIFT - FORK
SECTOR FRONT
BEARING
RETAINER
/if # # A J ,y f
HI/
PIN ^ / V ^ V '
SLOT ^ \x7
J8921-263
J8921-266
Fig. 31 Shift Sector Position
Fig. 33 Removing Front Bearing Retainer
(43) Remove the input gear snap ring (Fig. 34). (45) Remove the low range gear snap ring (Fig.
36).
It INPUT
11
GEAR
LOW RANGE
GEAR SNAP
J8921-267 RING
Fig. 34 Removing input Gear Snap Ring
(44) Press input and low range gears out of input
J8921-269
gear bearing and case (Fig. 35).
Fig. 36 Removing/Installing Low Range Gear Snap
Ring
(46) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 37).
THRUST
PRESS WASHERS
TOOLS%
INPUT-LOW
RANGE GEARS,
LOW RANGE
GEAR
INPUT
GEAR
J8921-268
RETAINER
J8921-214
Fig. 35 Removing Input And Low Range Gears
Fig. 37 Low Range Gear Disassembly
I P 2 4 2 TRANSFER CASE 21 - 2 i S
J (47) Inspect the low range annulus gear (Fig. 38).
The gear is not a serviceable component. If dam
aged, replace the gear and front case as an as
sembly.
LOW
Fig. 40 Removing Planet Gears And Thrust Washers

(52) Remove mainshaft and sprocket gears from
bottom case (Fig. 41). Note gear position for refer
Fig. 38 Inspecting Low Range Annulus Gear ence before separating them.
(48) Remove the oil seals from the rear retainer,
extension housing, oil pump and case halves.
(49) Mark differential case halves for reference.
(50) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 39).
Fig. 41 Removing Mainshaft And Sprocket Gears

Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
CASE S L O T S J8921-271 case and retainer seal surfaces.
Clean the oil pickup screen with solvent and dry it
Fig. 39 Separating Differential Case Halves with compressed air. Also use compressed air to re
(51) Remove thrust washers and planet gears from move solvent residue from all oil feed passages and
case pins (Fig. 40). channels.
Inspect the differential gears, thrust washers and (3) Remove the old bearing and install the new
case halves. Replace the mainshaft gear if the gear bearing with a driver handle and installer tool (Fig.
teeth or the brass ring on the underside of the gear 43).
are damaged. Replace the differential as an assembly
if the gears, case halves, or the pins in the lower case
half are damaged.
Inspect the case halves, extension housing and re
tainers for cracks, porosity, or damaged sealing sur
faces. Inspect the shafts, gears, chain and shift
FRONT
components for wear or damage. BEARING
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam
aged bearings as outlined in the assembly section.
T R A N S F E R CASE A S S E M B L Y
(1) Lubricate the transfer case components with
automatic transmission fluid or petroleum jelly
(where indicated) during assembly.
CAUTION; T h e bearing bores in various transfer

case components contain oil feed holes. Be sure re
placement bearings do not block these feed holes.
(2) Remove the front output shaft, front bearing

snap ring (Fig. 42).
Fig. 43 Replacing Output Shaft Front Bearing

(4) Install the front bearing snap ring (Fig. 42).
(5) Install new front output shaft oil seal (Fig. 44).
Fig. 42 Removing/installing Front Output Shaft

Front Bearing Snap Ring
Fig. 44 Installing Front Output Shaft Seal

(6) Press input gear bearing out of front case with (9) Remove input gear pilot bearing with slide
driver tool and shop press (Fig. 45). hammer and internal puller (Fig. 47).
INPUT INTERNAL SLIDE

GEAR PULLER HAMMER
BEARING
REMOVER
TOOL
J8921-220
Fig. 47 Removing Input Gear Pilot Bearing

J8921-218
(10) Install new pilot bearing with driver tools
Fig. 45 Removing Input Gear Bearing (Fig. 48).
(7) Install the snap ring on the new bearing.
(8) Install the new input gear bearing with a shop
press and wood block. Install the bearing far enough
to seat the snap ring against the case (Fig. 46). PILOT
BEARING
SNAP INPUT TOOLS
RING SHAFT
BEARING
INPUT
GEAR
J8921-221
Fig. 48 Installing Input Gear Pilot Bearing

J8921-219
Fig. 46 Seating Input Gear Bearing

21 - 3 0 2 NP242 TRANSFER CASE J
(11) Assemble low range gear, input gear thrust CAUTION: B e sure the input gear installer tool is
washers, input gear and input gear retainer (Fig. the proper size. T h e wrong siie tool c o u l d p u s h the
49). input gear pilot bearing too far into the gear bore
(Fig. 51). Also, d o not press against the e n d sur
THRUST
WASHERS faces of the low range gear. T h e gear c a s e a n d
thrust washers could b e d a m a g e d .
D O N O T PRESS DO NOT ALLOW

AGAINST T H E S E PRESS T O O L TO
SURFACES O F BEAR A G A I N S T
L O W RANGE GEAR PILOT BEARING
L O W RANGE
GEAR
INPUT
GEAR
RETAINER
J8921-214
Fig. 49 Low Range And input Gear Assembly

(12) Install low range gear snap ring (Fig. 50).
J8921-222
Fig. 51 Input Gear Installation

(16) Install new-input gear snap ring (Fig. 52).
INPUT
GEAR
L O W RANGE
GEAR S N A P
RING
J8921-269
Fig. 50 install Low Range Gear Snap Ring

(13) Lubricate input gear and low range gears
with automatic transmission fluid. J8921-267
(14) Start the input gear shaft into the front case
Fig. 52 Install Input Gear Snap Ring
bearing.
(15) Press the input gear shaft into the front bear
ing.
(17) Install new seal in front bearing retainer (Fig. (20) Install new sector shaft O-ring and bushing
53). (Fig. 55).
Fig. 53 install Front Bearing Retainer Seal Fig. 55 Installing Sector O-Ring And Bushing
(18) Apply 3 mm (1/8 in.) wide bead of Mopar gas (21) Install the shift sector.
ket maker, silicone adhesive sealer, or Loctite 518 to (22) Install new pads in low range fork (Fig. 56)
seal surface of front bearing retainer. (23) Assemble low range fork and hub (Fig. 56).
(19) Install the front bearing retainer (Fig. 54).
Tighten the retainer bolts to 16 ft. lbs. (21 N-m)
torque.
J8921-278
Fig. 56 Assembling Low Range Fork And Hub
J8921-276
Fig. 54 Installing Front Bearing Retainer

(24) Position low range fork and hub in case. Be (27) Install differential planet gears and new
sure low range fork pin is engaged in the shift sector thrust washers (Fig. 59). Be sure thrust washers
slot (Fig. 57). are installed at top and bottom of each planet
gear.
(28) Install differential mainshaft gear (Fig. 5 9 ) .
SHIFT
SECTOR
THRUST
W A S H E R S (12)
J8921-263 PLANET GEARS (6)
Fig. 57 Positioning Low Range Fork J8921-280
(25) Lubricate differential components with auto Fig. 59 Installing Mainshaft And Planet Gears
(26) Install sprocket gear in differential bottom (29) Align and position differential top case on bot
case (Fig. 5 8 ) . tom case (Fig. 6 0 ) . Align using scribe marks made at
disassembly.
(30) Install and tighten the differential case bolts
to specified torque.
SPROCKET
GEAR
BOTTOM TOP
CASE J8921-279 CASE
CASE
A L I G N M E N T MARKS
Fig. 58 Installing Differential Sprocket Gear BOTTOM
J8921-281
CASE
Fig. 60 Differential Case Assembly

N P 2 4 2 T R A N S F E R CASE 21 - 305
(31) Install first mainshaft bearing spacer on (35) Install the differential snap ring (Fig. 63).
mainshaft (Fig. 61).
(32) Install bearing rollers on mainshaft (Fig. 61). DIFFERENTIAL
SNAP
Coat bearing rollers with generous quantity o f RING
petroleum jelly to hold them i n place.
(33) Install remaining bearing spacer on mainshaft
(Fig. 61). Do not displace any bearings while install
ing spacer.
MAINSHAFT
BEARING
ROLLERS
BEARING
J8921-261
SPACERS
Fig. 63 Installing Differential Snap Ring

(36) Install the intermediate clutch shaft (Fig. 64).
Fig. 61 Installing Mainshaft Bearing Rollers and

Spacers
(34) Install the differential (Fig. 62). Do not dis
place the mainshaft bearings when installing the
differential.
INTERMEDIATE
CLUTCH
SHAFT
DIFFERENTIAL
J8921-260
Fig. 64 Installing Intermediate Clutch Shaft
- MAINSHAFT
J8921-283
Fig. 62 Differential Installation

21 - 3 0 1 I P 2 4 2 TRANSFER CASE J
(37) Install clutch shaft thrust washer (Fig. 65). MODE
FORK
SLIDER
CLUTCH
SHAFT
THRUST
RING
J8921-284
Fig. 67 Inspect Mode Fork Assembly

J8921-259 (40) Install mode sleeve in mode fork (Fig. 68).
Then install assembled sleeve and fork on mainshaft.
Fig. 65 Installing Clutch Shaft Thrust Washer Be sure mode sleeve splines are engaged in differen
(38) Install clutch shaft snap ring (Fig. 66). tial splines.
SNAP
RING
INTERMEDIATE
CLUTCH
SHAFT
J8921-258
Fig. 66 Installing Clutch Shaft Snap Ring

(39) Inspect mode fork assembly (Fig. 67). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 67). Replace J8921-257
worn, damaged components.
Fig. 68 Installing Mode Fork And Sleeve
(41) Install mode fork and mainshaft assembly in (45) Insert an easy-out in range fork lockpin to
case (Fig. 69). Rotate mainshaft slightly to engage hold it securely for installation (Fig. 71). Lockpin is
shaft with low range gears. slightly tapered on one end. Insert tapered end
into fork and rail.
(46) Insert lockpin through access hole and into
shift fork (Fig. 71). Then remove the easy-out and
seat the pin with pin punch.
Fig. 69 Installing Mainshaft And Mode Fork

(42) Rotate mode fork pin into shift sector slot. J8921-254
(43) Install shift rail (Fig. 70). Be sure rail is
seated in both shift forks. Fig. 71 Installing Low Range Fork Lockpin
(47) Install plug in lockpin access hole.
(48) Install transfer case shift lever and attaching
nut. Tighten nut to 30 N*m (22 ft. lbs.) torque.
(49) Install detent plunger, detent spring and de
tent plug in the case (Fig. 72).
Fig. 70 Installing Shift Rail Fig. 72 Installing Detent Pin, Spring And Plug
(44) Rotate shift sector to align lockpin hole in low
range fork with access hole in case.
(50) Install front output shaft (Fig. 73). (Fig. 75). Install new bearing with bearing driver
(51) Install drive chain (Fig. 73). Engage chain tools (Fig. 75). Lubricate bearing after installation.
with front output shaft sprocket teeth.
(52) Install drive sprocket (Fig. 73).
(53) Engage drive sprocket teeth with chain. Then
engage sprocket splines with mainshaft splines. SLIDE
HAMMER
DRIVE
SPROCKET
FRONT
OUTPUT
SHAFT
BEARING
INSTALLER
TOOLS
J8921-285
Fig. 73 installing Drive Chain And Sprocket J8921-234
(54) Install drive sprocket snap ring (Fig. 74).

Fig. 75 Installing Front Output Shaft Rear Bearing
(56) Assemble oil pump (Fig. 76). Replace any
pump components that are worn or damaged.
GEAR FEED
HOUSING HOUSING
DRIVE
SPROCKET
J8921-251
PUMP
Fig. 74 installing Drive Sprocket Snap Ring GEARS
(55) Replace front output shaft rear bearing. Re J892M95
move bearing with internal puller and slide hammer
Fig. 76 Oil Pump Assembly
J (57) Install new seal in oil pump feed housing (Fig. OIL PUMP
77).
SCREEN
J8921-287
Fig. 79 Installing Oil Screen And Pickup Tube

(60) Install magnet in front case pocket (Fig. 80).
Fig. 77 Installing Oil Pump seal

(58) Install new pickup tube O-ring in oil pump
(Fig. 78).
MAGNET
J8921-288
Fig. 80 Installing Case Magnet

PICKUP T U B E (61) Apply 3 mm (1/8 in.) wide bead of Mopar gas
O-RING ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of front case.
(62) Align and install rear case on front case. Be
sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
J8921-286
(63) Install and tighten the front case-to-rear case
bolts to 41 N*m (30 ft. lbs.) torque. Be sure to in
Fig. 78 Installing Pickup Tube O-Ring stall a washer under each of the bolts used at
the case dowel locations.
(59) Insert oil pickup tube in oil pump and attach (64) Tap rear retainer bearing out of retainer with
oil screen and connecter hose to pickup tube. Then hammer and brass drift.
install assembled pump, tube and screen in rear case (65) Install new bearing in rear retainer with
(Fig. 79). Be sure screen is seated in case slot as driver tools (Fig. 81).
shown. (66) Apply 3 mm (1/8 in.) wide bead of Mopar gas
21-310 NP242 TRANSFER CASE j
(70) Replace extension housing bushing with

driver tools (Fig. 83).
BUSHING
Fig. 81 Installing Rear Bearing In Retainer

seal surface of rear retainer.
(67) Install locating dowel in rear retainer (if re
moved) and install the retainer on the case. Tighten
#
the retainer bolts to 41 N m (30 ft. lbs.) torque.
(68) Install new rear bearing snap ring (Fig. 82).
L i f t mainshaft slightly to seat the snap ring i f neces J8921-237
sary.
Fig. 83 Replacing Extension Housing Bushing
(69) Remove extension housing seal i f not removed
previously. (71) Install new extension housing oil seal (Fig.
84).
J8921-238
Fig. 82 Installing Rear Bearing Snap Ring Fig. 84 Replacing Extension Housing Seal
J NP242 TRANSFER CASE 21-311

seal surface of extension housing.
(73) Install extension housing on case. Tighten
housing bolts to 41 N°m (30 ft. lbs.) torque.
(74) Install front yoke. Secure yoke with new seal
#
washer and nut. Tighten nut to 149 N m (110 ft. lbs.)
torque.
(75) Install new gasket on vacuum switch and in
stall switch in the case. Tighten switch to 27 N*m (20
ft. lbs.) torque.
(76) Install speedometer components (Fig. 85).
(77) Install and tighten drain plug to 47 N*m (35
ft. lbs.) torque.
(78) After installing transfer case, refill with rec
ommended transmission fluid.
(79) Tighten fill plug to 47 N«m (35 ft. lbs.) torque. Fig. 85 Speedometer Components
(80) Adjust transfer case shift linkage.
LEGEND FOR NP242 TRANSFER CASE
1 F R O N T BEARING RETAINER A N D SEAL 20 DRAIN/FILL P L U G S 38 OIL PUMP PICKUP T U B E A N D S C R E E N

2 F R O N T CASE 21 REAR BEARING RETAINER 39 MAINSHAFT BEARING ROLLERS
3 SHIFT SECTOR 22 EXTENSION HOUSING 40 DRIVE SPROCKET
4 L O W RANGE F O R K A N D INSERTS 23 B U S H I N G A N D OIL SEAL 41 DRIVE CHAIN
5 SHIFT RAIL 24 VACUUM S W I T C H 42 S N A P RING
6 SHIFT BRACKET 25 MAGNET 43 OIL PUMP SEAL
7 SLIDER BRACKET 26 T H R U S T RING 44 OIL PUMP
8 B U S H I N G A N D SPRING 27 S N A P RING 45 REAR BEARING A N D S N A P RING
9 M O D E FORK A N D INSERTS 28 SHIFT SLEEVE 46 F R O N T O U T P U T SHAFT REAR BEARING
10 BUSHING 29 L O W RANGE GEAR 47 S N A P RING
11 FORK SPRING 30 PILOT B U S H I N G 48 DRIVEN SPROCKET
12 BUSHING (INPUT GEAR/MAINSHAFT) 49 F R O N T O U T P U T SHAFT
13 VENT TUBE ASSEMBLY 31 F R O N T O U T P U T SHAFT F R O N T 50 MAINSHAFT BEARING SPACERS
14 INPUT GEAR BEARING A N D BEARING A N D S N A P RING 51 SHIFT LEVER W A S H E R A N D N U T
S N A P RING 32 INTERMEDIATE CLUTCH SHAFT 52 SHIFT LEVER
15 L O W RANGE GEAR S N A P RING 33 SHIFT SLEEVE 53 SECTOR O-RING A N D SEAL
16 RETAINER, L O W RANGE GEAR 34 S N A P RING 54 D E T E N T PIN, SPRING A N D PLUG
17 T H R U S T W A S H E R , L O W RANGE GEAR 35 MAINSHAFT 55 SEAL PLUG
18 INPUT GEAR 36 DIFFERENTIAL ASSEMBLY 56 F R O N T YOKE N U T , SEAL W A S H E R ,
19 REAR CASE 37 OIL PUMP T U B E O-RING YOKE, SLINGER A N D OIL SEAL
J8921-291
21 - 314 TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TORQUE SPECIFICATIONS-AX 15 MANUAL TRANSMISSION
Description Torque
Access Plugs 19 N » m (14 ft. lbs.)

Adapter Housing Bolts 37 N « m (27 ft. lbs.)
Backup Light Switch 37 N » m (27 ft. lbs.)
Drain and Fill Plugs 37 N « m (27 ft. lbs.)
Front Bearing Retainer Bolts 17 N » m (12 ft. lbs.)
Interlock and Detent Ball Plugs 19 N » m (14 ft. lbs.)
Propeller Shaft Clamp
Screws 16-23 N » m (140-200 in. lbs.)
Rear AAount-To-Transmission
Bolts 33-60 N » m (24-44 ft. lbs.)
Rear Mount Clevis B o l t / N u t . . . . . . . 54-75 N « m (40-55 ft. lbs.)
Rear Mount-To-
Crossmember Nuts. 33-49 N » m (24-36 ft. lbs.)
Restrictor Pins 19 N » m (14 ft. lbs.)
Reverse Shift Arm
Bracket Bolts 18 N » m (13 ft. lbs.)
Shift Arm Set Screw 38 N » m (28 ft. lbs.)
Shift Fork Set Screws 20 N » m (15 ft. lbs.)
Shift Knob Nut 20-34 N » m (15-25 ft. lbs.)
Shift Lever Floor
Cover Screws 2-3 N « m (17-30 in. lbs.)
Shift Tower Bolts 18 N » m (13 ft. lbs.)
Transfer Case Mounting Nuts . . . . . 30-41 N « m (22-30 ft. lbs.)
J9321-89
TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21-315
SELECTIVE SNAP RING CHART-AX 15 MANUAL TRANSMISSION
INPUT OUTPUT
SHAFT SHAFT
BEARING REAR
SNAP SNAP
RING RING
FIFTH
GEAR
SNAP
RING
CLUSTER
FRONT
BEARING
SNAP
RING
I N P U T SHAFT BEARING SWAP R I N G 1-2 H U B SWAP RING

, MARK THICKNESS I.D. M A R K
A 2.10-2.15 mm
micicwess
B 2.15-2.20 mm B 2.35-2.40 mm
C 2.20-2.25 mm C 2.40-2.45 mm
D 2.25-2.30 mm D 2.45-2.50 mm
E 2.30-2.35 mm E 2.50-2.55 mm
F 2.35-2.40 mm F 2.55-2.60 mm
G 2.40-2.45 mm G 2.60-2.65 mm
O U S T E R EROMT BEARING SWAP RING O U T P U T SHAFT REAR SWAP R I N G

I.D. M A R K THICKNESS I.D. M A R K THICKNESS
A 2.00-2.05 mm A 2.75-2.80 mm
B 2.05-2.10 mm B 2.80-2.85 mm
C 2.10-2.15 mm C 2.85-2.90 mm
D 2.15-2.20 mm D 2.90-2.95 mm
E 2.20-2.25 mm E 2.95-3.00 mm
F 3.00-3.05 mm
G 3.05-3.10 mm
H 3.10-3.15 mm
1 3.15-3.20 mm
J 3.20-3.25 mm
K 3.25-3.30 mm
L 3.30-3.35 mm
3-4 H U B SWAP RING FIFTH GEAR SWAP RIWG

I.D. M A R K THICKNESS I.D. M A R K THICKWESS
A 1.80-1.85 mm A 2.80-2.85 mm
B 1.85-1.90 mm B 2.85-2.90 mm
C 1.90-1.95 mm C 2.90-2.95 mm
D 1.95-2.00 mm D 2.95-3.00 mm
E 2.00-2.05 mm E 3.00-3.05 mm
F 2.05-2.10 mm F 3.05-3.10 mm
G 2.10-2.15 mm G 3.10-3.15 mm
H 3.15-3.20 mm
J8921-1131
21-316 TRANSMISSION/TRANSFER CASE SPECIFICATIONS J
32RH GENERAL SPECIFICATIONS
TRANSMISSION TYPE T h r e e - S p e e d Automatic w i t h T o r q u e Converter and g e a r t y p e

oil pump.
F L U I D C A P A C I T Y (converter) 17.1 Pts. 8.1 Liters
RECOMMENDED FLUID M o p a r A T F Plus Type 7176, o r Dexton II®
FLUID COOLING METHOD W a t e r H e a t Exchanger in R a d i a t o r
GEAR RATIOS: First: Second: Third: Reverse:
2.74 1.54 1 to 1 2.21
OIL PUMP GEAR CLEARANCES:
O u t e r G e a r to Case Bore 0.0035 to 0.0075 inch
E n d Clearance-Gears 0.0004 to 0.0025 inch
P L A N E T A R Y G E A R T R A I N E N D PLAY 0.005 to 0.048 inch
I N P U T S H A F T E N D PLAY 0.022 to 0.091 inch
CLUTCH PLATE CLEARANCE:
Front Clutch 0.075 to 0.152 inch
R e a r Clutch 0.025 to 0.045 inch
CLUTCH DISCS:
N u m b e r o f Front Clutch Discs 5
N u m b e r o f R e a r Clutch Discs 4
BAND ADJUSTMENTS:
Kickdown (Front) T u r n s * 2-1/2
Low-Reverse (Rear) T u r n s * 4
* Backed o f f f r o m 72 inch-pounds (5 Nm)
J9221-33
32RH SNAP RING/THRUST WASHER/THRUST PLATE SPECIFICATIONS
COMPONENT THICKNESS SPECIFICATION
Front Clutch T h r u s t W a s h e r 0.061 in.

(on reaction shaft s u p p o r t hub)
R e a r Clutch T h r u s t W a s h e r 0.061 in.

(on clutch retainer)
O u t p u t Shaft T h r u s t Plate 0 . 0 6 0 - 0 . 0 6 3 in.

(on O u t p u t shaft pilot hub)
O u t p u t Shaft T h r u s t W a s h e r 0 . 0 5 2 - 0 . 0 5 4 in.
(in rear clutch hub) 0 . 0 6 8 - 0 . 0 7 0 in.
0 . 0 8 3 - 0 . 0 8 5 in.
Rear Clutch Pack Snap ring 0.068 in.

0.060 in.
0.076 in.
0.098 in.
Planetary Geartrain S n a p Ring 0 . 0 4 0 - 0 . 0 4 4 in.

(At f r o n t end o f output shaft) 0 . 0 6 2 - 0 . 0 6 6 in.
0 . 0 8 2 - 0 . 0 8 6 in.
J9221-32
J T R A N S M I S S I O N / T R A N S F E R CASE S P E C I F I C A T I O N S 21 - 3 1 7
32RH PRESSURE TEST SPECIFICATIONS
Closed Throttle 34-207 kPa (5-30 psi)

Lube Pressure
Full Throttle 34 207 kPa (5-30 psi)
Closed Throttle 372-414 kPa (54-60 psi)

Line Pressure
1000 rpm 648 kPa (94 psi)
Front Servo Release Third Gear Only No more than 21 kPa (3 psi) lower than line pressure.
1 Range No more than 21 kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle, builds to
Rear Servo Apply
R Range 1862 kPa (270 psi) at 1600 rpm.
Pressure should respond smoothly to changes in mph and return to 0-7 kPa (0-1V2 psi) when
D Range
Governor stopped with transmission in D, 1,2. P r e s s u r e a b o v e 7 k P a (1 Vi p s i ) a t s t a n d s t i l l
Closed Throttle
will prevent transmission from downshifting.
J8921-752
32RH TORQUE SPECIFICATIONS
In. Lbs. N*m In. Lbs. N*m
Cooler Line Fittings 155 18 Oil Pan Bolt 150 17

Cooler Line Nuts 7* 10 Oil Pump Bolt 175 20
Drive Plate-To-Crankshaft Bolt 55* 75 Rear Support Bolt 100 11
Drive Plate-To-Converter Bolt 270 31 Overrunning Clutch Cam Bolts 100 11
Adapter Housing Bolts 32* 43 Overrunning Clutch Cam
Adapter Housing To Insulator Bolt 50* 68 Set Screw (A727) 3* 5
Governor Body-To-Park Gear Bolts . . . 95 11 Pressure Test Plugs 120 14
Kickdown Band Adjusting Reaction Shaft Support Bolts 175 20
Screw Lock Nut 30* 41 Low-Rev. Band Adjusting
Front Band Lever Pin Access Plug 150 17 Screw Lock Nut 25* 34
Solenoid Wiring Connector 150 17 Speedometer Adapter Clamp Screw . . 100 11
Neural Switch 25* 34 Transmission-To-Engine Bolt 30* 41
Valve Body Screws 35 4
Valve Body-To-Transmission Case Bolts. 105 12
'Foot Pounds *Foot Pounds
J9121-200
21-318 TRANSMISSION/TRANSFER CASE SPECIFICATIONS — J
AW-4 GENERAL SPECIFICATIONS
Gear Ratios:
First . . . . . . . . . . . 2.804:1
Second 1531:1
Third 1.000:1
Fourth (Overdrive) 0.753:1
Reverse 2.393:1
Transmission Fluid J e e p automatic transmission f l u i d o r D E X R O N ® II
Fluid L e v e l . T o " F u l l " mark w i t h f l u i d hot (normal operating temperature)
Fluid Capacity (all models) 8 . 0 Liters ( 8 . 4 5 qts.)
Test Specifications
Stall Speed:
In D Range and Reverse 2 1 0 0 - 2 4 0 0 rpm
L i n e Pressure:
In D at Curb Idle 6 1 - 7 0 psi ( 4 2 1 - 4 8 1 kPa)

In D at W O T • 1 7 3 - 2 0 9 psi ( 1 1 9 6 - 1 4 4 2 kPa)
In Reverse at C u r b Idle 7 5 - 9 0 psi ( 5 1 9 - 6 1 8 kPa)
In Reverse at W O T 2 1 3 - 2 6 3 psi ( 1 4 7 1 - 1 8 1 4 kPa)
T i m e L a g Test:
Engagement in D Range . . 1.2 seconds
Engagement in Reverse . 1.5 seconds
Valve B o d y S o l e n o i d Resistance 1 1 - 1 5 ohms
Transmission Fluid N o r m a l O p e r a t i n g Temperature 5 0 - 8 0 ° C ( 1 2 2 - 1 7 6 ® F)
T P S Input Voltage ( A U ) 5 . 0 Volts (approx.)
T P S O u t p u t Voltage
4-Cylinder . . . . . . . . . . . 0 . 2 Volts (approx.)
6-Cylinder 4 . 2 Volts (approx.)
J9121-401
J T R A N S M I S S I O N / T R A N S F E R CASE S P E C I F I C A T I O N S 21-319
AW-4 OIL PUMP WEAR LIMITS
Drive Gear
Tip Clearance:
Standard 0.11 -0.14 mm (0.0043-0.0055 in.)
Maximum Allowance 0.3 mm (0.012 in.)
Gear-to-Pump Body
End Clearance:
Standard 0.02-0.05 mm (0.0008-0.0020 in.)
Maximum Allowance 0.1 mm (0.004 in.)
Driven Gear-to-Pump
Body Clearance:
Standard 0.07-0.15 mm (0.0028-0.0059 in.)
Maximum Allowance ......... 0.3 mm (0.012 in.)

J8921-740
AW-4 CLUTCH DISC AND PLATE THICKNESS
Component M i n i m u m Allowable Thickness
Clutch Disc (all exceptfirst-reverseand forward clutch discs) 1.84 mm (0.0724 in.)
6-Cylinder Forward Clutch Disc 1.51 mm ( 0 . 0 5 9 4 in.)
6 Cylinder Direct Clutch Plates:

Thin Plate 0) 2.3 mm (0.905 in.)
Thick Plates (3) 3.0 mm (0.118 in.)
6-Cylinder Forward Clutch Plate 1.8 mm (0.070 in.)
First-Reverse Brake Disc (all) 1.51 mm (0.0594 in.)
J9121-402
21 - 320 TRANSMISSION/TRANSFER CASE SPECIFICATIONS J
AW-4 BUSHING AND PISTON CLEARANCE
B U S H I N G I N S I D E DIAMETER (MAXIMUM)
Bushing Location M a x i m u m Allowance Inside Diameter
Extension H o u s i n g 3 8 . 0 9 mm ( 1 . 4 9 9 6 in.)
Direct Clutch D r u m 5 3 . 9 7 mm ( 2 . 1 2 4 8 in.)
O v e r d r i v e Planetary G e a r 1 1 . 2 7 mm ( . 4 4 3 7 in.)
O v e r d r i v e Direct Clutch D r u m 2 7 . 1 1 mm ( 1 . 0 6 7 3 in.)
S t a t o r S h a f t (Front) 2 1 . 5 8 mm ( . 8 4 9 6 in.)
S t a t o r S h a f t (Rear) 2 7 . 0 8 mm ( 1 . 0 6 6 1 in.)
O i l Pump B o d y 3 8 . 1 9 mm ( 1 . 5 0 3 5 in.)
Transmission Case 3 8 . 1 8 mm ( 1 . 5 0 3 1 in.)
PISTON STROKE LENGTH
Piston Location Specification
Direct Clutch (all) 1 . 3 7 - 1 . 6 7 mm ( . 0 5 3 9 - . 0 6 5 7 in.)
6 - C y l i n d e r Overdrive Brake 1 . 4 0 - 1 . 7 0 mm ( . 0 5 5 1 - . 0 6 6 9 in.)
Second Coast Brake (all) 1 . 5 - 3 . 0 mm ( . 0 5 9 - . 1 1 8 in.)
6 - C y l i n d e r F o r w a r d Clutch 3 . 5 5 - 3 . 7 3 ( . 1 3 9 7 - . 1 4 6 8 in.)
O v e r d r i v e Direct Clutch (all) 1 . 8 5 - 2 . 1 5 mm ( . 0 7 2 8 - . 0 8 4 6 in.)
E N D PLAY A N D CLEARANCE
Component Specification
Output Shaft End Play . 2 7 - . S 6 mm ( . 0 1 0 6 - . 0 3 3 9 in.)
6 - C y l i n d e r First-Reverse Brake Pack Clearance . 7 0 - 1 . 2 0 mm ( . 0 2 8 - . 0 4 7 in.)
6 - C y l i n d e r Second Brake Pack Clearance . 6 2 - 1 . 9 8 mm ( . 0 2 4 - . 0 7 8 in.)
J9121-403
J TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 321
AW-4 RETAINER AND PISTON SPECIFICATIONS
OVERDRIVE BRAKE R E T A I N E R S E L E C T I O N
Retainer No. Thickness Retainer N o . Thickness
26 3.3 mm (.130 in.) n 3.8 mm (.150 in.)
25 3.5 mm (.138 in.) 23 3.9 mm (.154 in.)
12 3.6 mm (.142 in.) N o t Marked 4.0 mm (.157 in.)
24 3.7 mm (.146 in.) — —
DIRECT CLUTCH RETAINER SELECTION
Retainer No* Thickness Retainer N o . Thickness
33 3.0 mm (.118 in.) 29 3.4 mm (.134 in.)
32 3.1 mm (.122 in.) 28 3.5 mm (.138 in.)
31 3.2 mm (.126 in.) 27 3.6 mm (.142 in.)
30 3.3 mm (.130 in.) 34 3.7 mm (.146 in.)
OVERDRIVE CLUTCH RETAINER SELECTION

16 3.6 mm (.142 in.) 19 3.3 mm (.130 in.)
17 3.5 mm (.138 in.) 20 3.2 mm (.126 in.)
18 3.4 mm (.134 in.) 21 3.1 mm (.122 in.)
S E C O N D COAST B R A K E P I S T O N R O D SELECTION
Rod R o d Length
No. 1 71.4 mm (2.811 in.)
No.2 72.9 mm (2.870 in.)
F O R W A R D CLUTCH RETAINER SELECTION
Retainer N o . Thickness Retainer No. Thickness
42 4.0 mm (.157 in.) 61 3.0 mm (.118 in.)
44 3.8 mm (.149 in.) 62 3.6 mm (.142 in.)
45 3 . 4 mm (.134 in.) 63 4.2 mm (.165 in.)
60 3.2 mm (.126 in.) 64 4.4 mm (.173 in.)
FIRST-REVERSE B R A K E CLEARANCE SELECTION

50 5.0 mm (.197 in.) 53 4,4 mm (.173 in.)
51 4.8 mm (.189 in.) 54 4.2 mm (.165 in.)
52 4.6 mm (.181 in.) 55 4.0 mm (.157 in.)
J9121-404
21 - 322 TRANSMISSION/TRANSFER CASE SPECIFICATIONS J
AW-4 VALVE BODY CHECK BALL DIMENSIONS
Check B o i l Diameter
(A) R u b b e r Ball 6.35 mm (0.250 in.)
© Rubber Ball 5.535 mm (.218 in.)
J9121-405
AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS
Component Discs Required Plates Required Retainers Required
6-Cylinder Overdrive Brake 4 3 2
6-Cylinder Second Brake 5 5
6-Cylinder Overdrive Direct Clutch 2 2
6-Cylinder Direct Clutch 4 4
6-Cylinder Forward Clutch 6 6
6-Cylinder First-Reverse Brake 7 7
J9121-406
T R A N S M I S S I O N / T R A N S F E R CASE S P E C I F I C A T I O N S 21 - 323
AW-4 ACCUMULATOR COMPONENT IDENTIFICATION
Component Approximate
Outside Diameter
SECOND BRAKE ACCUMULATOR SPRING A 14.17 mm (.558 in.)
PISTON B 36.9 mm (1.453 in.)
SPRING C 19.91 mm (.784 in.)
DIRECT CLUTCH ACCUMULATOR SPRING D 12.07 mm (.475 in.)
PISTON E 36.9 mm (1.453 in.)
SPRING F 20.19 mm (.795 m.)
SPRING G 14.81 mm (.583 in.)
OVERDRIVE BRAKE ACCUMULATOR SPRING H 14.10 mm (.555 in.)
PISTON J 31.9 mm (1.256 in.)
SPRING K 19.99 mm (.785 in.)
OVERDRIVE CLUTCH ACCUMULATOR SPRING L 14.0 mm (0.551 in.)
SPRING M 20.3 mm (0.799 in.)
PISTON N 29.9 mm (1.177 in.)
J9121-407
AW-4 VALVE AND SPRING IDENTIFICATION
0)
inning
(2)
J
«^--D00--c=O3OO-
(3)
mmm- - cO=0=0=0> - - DO Spring Free Length
(1) Downshift Plug 27.3 mm (1.074 in.)

(4)
1 = 0 0 - 0 0
(2) Throttle Valve 20.6 mm (.811 in.)
(3) 3-4 Shift Valve 30.8 mm (1.212 in.)
I (4) Second Coast Modulator Valve 25.3 mm (.996 in.)
0=00- - -=o=o>- (5) Lockup Relay Valve 21.4 mm (.843 in.)

(5)
(6) Secondary Regulator Valve 30.9 mm (1.217 in.)
(6)
(7) Cut-Back Valve 21.8 mm (.858 in.)
(8) 2-3 Shift Valve 30.8 mm (1.212 in.)

(7)
WMW«--D=0--[ffl (9) Low Coast Modulator Valve 27.8 mm (1.094)
8
< >
(9)
0 0 = ] - -DO
Spring S p r i n g Length
9 9
m 1 (1) Check Valve 20.2 mm (.797 in.)
1 (2)
(2) Pressure Relief Valve 11.2 mm (.441 in.)
(3) (3) 1-2 Shift Valve 30.8 mm (1.213 in.)

Q=CfcOC3=s mmm ffl)
(4) Primary Regulator Valve 62.3 mm (2.453 in.)
(5) Accumulator Control Valve 29.8 mm (1.173 in.)

(4)
crane
5
'»
immtm C=0o=O" | 'jg urJcl J9121-408
4 ——• TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 325
AW-4 TORQUE SPECIFICATIONS
Description Torque Description Torque
Converter Housing Bolts Rear Mount-To-Transmission

10 mm 32-36 N®m (23-27 ft. lbs.) Bolts. 60-81 N®m (44-66 ft. lbs.)
12 mm 55-59 N®m (40-43 ft. lbs.) Rear Mount-To-Clevis Bracket
Cooler Line Retaining Bolt/Nut 54-75 N®m (40-55 ft. lbs.)
Clip Nuts 2-4 N®m (18-35 in. lbs.) Rear Mount Clevis Bracket-To-
Cooler Line Bracket Crossmember Nuts 33-49 N®m (24-36 ft. lbs.)
Nuts . 5-11 N » m (48-96 in. lbs.) Shift Cable Bracket Screws
Cooler Line Fitting Nuts At Transmission 25-39 N®m (221-345 in. lbs.)
(atauto, trans, fittings) 18-23 N®m (160-200 in. lbs.) Shift Lever Mounting
Detent Spring Bolt 9-11 N®m (80-96 in. lbs.) Cover Screws 1-2 N®m (9-20 in. lbs.)
Dust Cover Nuts/Bolts 18-23 N®m (159-203 in. lbs.) Shift Lever Housing Nuts 16-26 N®m (141-230 in. lbs.)
Extension Housing Bolts 32-36 N®m (23-27 ft. lbs.) Solenoid Harness Bolt 6-8 N®m {57-75 in. lbs.)
Fill Tube Bracket Bolt 50-64 N®m (37-47 ft. lbs.) Speedometer Adapter
Neutral Switch Clamp Screw. 10-12 N®m (90-110 in. lbs.)
Bolt 12-14 N®m (8-10 ft. lbs.) Speed Sensor Coupling Nut 14-20 N®m (125-175 in. lbs.)
Nut 6-8 N®m (53-70 in. lbs.) Throttle Cable Engine
OD Support Bolt (to case) 23-27 N®m (18-20 ft. lbs.) Bracket Screws 7-11 N®m (63-94 in. lbs.)
Throttle Cable Retaining
Oil Pan Bolts 6-8 N®m (53-70 in. lbs.)
Screw (at transmission) 8-10 N®m (70-98 in. lbs.)
Oil Pan Drain Plug 19-21 N®m (14-16 ft. lbs.)
Transfer Case Mounting Nuts 30-41 N®m (22-30 ft. lbs.)
Oil Pump Bolt
Transmission Shift Lever Nut 15-17 N®m (134-154 in. lbs.)
(to case) 21-23 N - m (16-18 ft. lbs.)
Oil Pump Bolt Transmission-To-Engine
(to stator shaft) 9-11 N®m (80-96 in. lbs.) Block Bolts 50-64 N®m (37-47 ft. lbs.)
Oil Screen Bolt 9-11 N®m (80-96 in. lbs.) Valve Body Bolts (to case) 9-11 N®m (80-96 in. lbs.)
Park Pawl Bracket 9-11 N®m (80-96 in. lbs.) Valve Body Bolts (to valve body) 6-7 N®m (54-58 in. lbs.)
Propeller Shaft Clamp
Screws 16-23 N®m (140-200 in. lbs.) J9321-88
NP231/NP242 TORQUE SPECIFICATIONS
Description Torque
Detent Plua 16-24 N«m ( 1 2 - 1 8 ft. lbs.)
Differential Case Bolt 17-27 N»m (150-240 in. lbs.)
D r a i n / F i l l Plugs... 40-54 N»m ( 3 0 - 4 0 ft. lbs.)
Extension Housing Bolt 35-46 N»m ( 2 6 - 3 4 ft. lbs.)
Front Bearing Retainer Bolt... 16-27 N»m ( 1 2 - 2 0 ft. lbs.)
Front Case-To-Rear
Case Bolt 3 5 - 4 6 N » m ( 2 6 - 3 4 ft. lbs.)
Front Yoke Nut 1 2 2 - 1 7 6 N T n ( 9 0 - 1 3 0 ft. lbs.)
O i l Pump Screw 1.4-1.8 N » m ( 1 2 - 1 5 in. lbs.)
Range Lever Nut 2 7 - 3 4 N * m ( 2 0 - 2 5 ft. lbs.)
Rear Retainer Bolt. 3 5 - 4 6 N * m ( 2 6 - 3 4 ft. lbs.)
Transfer Case Mounting Nuts 3 5 - 4 7 N » m ( 2 6 - 3 5 ft. lbs.)
U-Joint Clamp Bolts 1 9 N * m ( 1 7 0 i n . lbs.)
Vacuum Switch.. 2 0 - 3 4 N » m ( 1 5 - 2 5 ft. lbs.)
J9321-95
J WHEELS AND TIRES 22 - 1
WHEELS AND TIRES
CONTENTS
page page
SPECIFICATIONS 11 VEHICLE VIBRATION 9

TIRES 1 WHEELS 6
TIRES
INDEX
page page
Cleaning of Tires 2 Rotation 3
General Information 1 Tire Inflation Pressures 2
Pressure Gauges 2 Tire Noise or Vibration 4
Repairing Leaks 3 Tire Wear Patterns 4
Replacement Tires 2 Tread Wear Indicators 3
GENERAL INFORMATION not always printed on the tire side wall. The letter S
Tires are designed for each specific vehicle. They indicates that the tire is speed rated up to 112 mph.
provide the best overall performance for normal op • Q up to 100 mph
eration. The ride and handling characteristics match • T up to 118 mph
the vehicle's requirements. With proper care they • U up to 124 mph
will give excellent reliability, traction, skid resis • H up to 130 mph
tance, and tread life. These tires have specific load • V up to 149 mph
carrying capacities. When correctly inflated, they • Z more than 149 mph (consult the tire manufac
will operate properly. turer for the specific speed rating)
Tires used in cool climates, and with light loads An All Season type tire will have either M + S , M
will have a longer life than tires used in hot climates & S or M - S (indicating mud and snow traction) im
with heavy loads. Abrasive road surfaces will accel printed on the side wall.
erate tire wear.
Driving habits have more effect on tire life than RADIAL-PLY TIRES
any other factor. Careful drivers will obtain much Radial-ply tires improve handling, tread life, ride
greater mileage than careless drivers. quality and decrease rolling resistance.
Driving habits that shorten the life of any tire; Radial-ply tires must always be used in sets of
• Rapid acceleration and deceleration four. Under no circumstances should they be used on
• Severe application of brakes the front only. They may be mixed with temporary
• High-speed driving spare tires when necessary, but reduced speeds are
• Taking turns at excessive speeds recommended.
• Striking curbs and other obstacles Radial-ply tires have the same load-carrying capac
It is very important to follow the tire rotation in ity as other types of tires of the same size. They use
terval the same recommended inflation pressures.
IDENTIFICATION SPARE TIRE (TEMPORARY)

Tire type, size, aspect ratio and speed rating are The compact spare tire is designed for emergency
encoded in the letters and numbers imprinted on the use only. The original tire should be repaired and re
side wall of the tire. Refer to the chart to decipher installed at the first opportunity. Refer to Owner's
the tire identification code (Fig. 1). Manual for complete details.
Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is
22 - 2 WHEELS AND TIRES
METRIC T I R E SIZES
THIN TIRE
P 205 / 75 R 15 TREAD
AREAS
TIRE TYPE
r
ASPECT RATIO
P - PASSENGER (SECTION HEIGHT)
T - TEMPORARY (SECTION WIDTH)
C - COMMERCIAL 70
LT - LIGHT TRUCK 75
80
SECTION WIDTH
(MILLIMETERS) CONSTRUCTION TYPE
185 R - RADIAL
195 B - BIAS • BELTED
205 D - DIAGONAL (BIAS)
ETC.
J9222-1
Fig. 2 Under Inflation Wear

THIN TIRE
TREAD
AREA
J9322-6
Fig. 1 Tire Size Identification

TIRE GHAMS
Tire snow chains may be used on certain models.
Refer to Owner's Manual for more information. J9222-2
CLEANING OF TIRES Fig. 3 Over Inflation Wear

Steam cleaning may be used for cleaning.
checked cold once per month. Tire pressure de
DO NOT use gasoline or wire brush for cleaning.
creases when the outside temperature drops.
DO NOT use mineral oil or an oil-based solvent.
Inflation pressures specified on the placards are al
PRESSURE GAUGES ways cold inflation pressure. Cold inflation pres
High-quality, dial-type, air-pressure gauges are sure is obtained after the vehicle has not been
recommended. After checking with the gauge, re operated for at least 3 hours. Tire inflation pressures
place valve caps and tighten finger tight. may increase from 2 to 6 pounds per square inch
(psi) during operation. Do not reduce this normal
TIRE INFLATION PRESSURES pressure build-up.
Under inflation (Fig. 2) causes rapid shoulder wear Vehicles loaded to the maximum capacity should
and tire flexing. not be driven at continuous speeds above 75 mph
Over inflation (Fig. 3) causes rapid center wear (120 km/h).
and loss of the tire's ability to cushion shocks.
Improper inflation can cause; W A R N I N G : OVER OR UNDER INFLATED TIRES C A N
• Uneven wear patterns A F F E C T VEHICLE HANDLING A N D C A N FAIL SUD
• Reduced tread life D E N L Y , R E S U L T I N G IN L O S S O F V E H I C L E CON
• Reduced fuel economy TROL
• Unsatisfactory ride
1
• Cause the vehicle to drift
Refer to the Owner's Manual for information re REPLACEMENT TIRES
garding proper tire inflation pressure. OEM tires provide a proper balance of many fea
This pressure has been carefully selected to provide tures such as;
for safe vehicle operation. Tire pressure should be • Ride
J WHEELS AND TIRES 22 - 3
• Noise TREAD WEAR INDICATORS

• Handling Tread wear indicators are molded into the bottom
• Durability of the tread grooves. When tread is 1.6 mm (1/16 in.),
• Tread life the tread wear indicators will appear as a 13 mm
• Traction (1/2 in.) band.
• Rolling resistance Tire replacement is necessary when indicators ap
• Speed capability pear in two or more grooves, or if localized balding
We recommend that tires equivalent to the original occurs (Fig. 5).
equipment tires be used when replacement is needed.
TREAD TREAD
Refer to the placard on the vehicle or the ACCEPTABLE UNACCEPTABLE
Owner's Manual for the correct replacement
tire.
Failure to use original equipment replacement
tires may adversely affect the handling of the vehi
cle.
The use of oversize tires is not recommended.
They may cause interference with vehicle suspension
and steering travel. This can cause tire damage or
failure.
WARNING: F A I L U R E T O E Q U I P T H E V E H I C L E WITH
T I R E S HAVING A D E Q U A T E LOAD C A P A B I L I T Y CAN
RESULT IN S U D D E N T I R E F A I L U R E .
ROTATION WEAR
INDICATOR
Tires on the front and rear axles operate at differ
ent loads and perform different steering, driving, and J8922-5
braking functions. For these reasons;
• They wear at unequal rates Fig. 5 Tread Wear Indicators
• Tend to develop irregular wear patterns REPAIRING LEAKS
These effects can be reduced by timely rotation of For proper repairing, a radial tire must be removed
tires. The benefits of rotation are especially worth from the wheel. Repairs should only be made if the
while. Rotation will: puncture is in the tread area (Fig. 6). If outside the
• Increase tread life tread area the tire should be replaced.
• Help to maintain mud, snow, and wet traction lev
. REPAIRABLE
els AREA
• Contribute to a smooth, quiet ride
The suggested method of tire rotation is the same
side front to rear pattern (Fig. 4). Other rotation
methods can be used, but they will not provide all
the tire longevity benefits.
FRONT
J9222-8
Fig. 4 Tire Rotation Pattern

J8922-6
Fig. 6 Tire Repair Area

22 - 4 WHEELS AND TIRES 4
• H A V E TIRE INSPECTED FOR FURTHER USE. RN797
Fig. 7 Abnormal Tire Tread Wear Patterns

Deflate tire completely before dismounting tire tion on noise level. Differential and exhaust noise
from the wheel. Use lubrication such as a mild soap will change in intensity as speed varies. Tire noise
solution when dismounting or mounting tire. Use will usually remain constant.
tools free of burrs or sharp edges.
Before mounting tire on wheel, make sure all rust TIRE WEAR PATTERNS
scale is removed from the rim. Repaint or seal if nec Under inflation results in faster wear on shoulders
essary. of tire. Over inflation causes faster wear at center of
tread.
TIRE NOISE OR VIBRATION Excessive camber causes the tire to run at an angle
The radial-ply tire on your vehicle is more sensi to the road. One side of tread is worn more than the
tive to improper mounting, or imbalance. other.
To determine if tires are the cause of vibration, Excessive toe-in or toe-out causes wear on the
drive the vehicle over a smooth road at different tread edges of the tire, from dragging of tire. There
speeds. Note the effect of acceleration and decelera- is a feathered effect across the tread (Fig. 7 ) .
WHEELS AND TIRES 22 - 5
LEAD CORRECTION CHART
ADJUST TIRE PRESSURE ROAD TEST OK

T O REDUCED LOAD O N
P R E S S U R E PLACARD
I
CAR LEADS
CROSS SWITCH FRONT
TIRE & W H E E L ASSEMBLIES
I OK
ROAD TEST
I
±
CAR L E A D S CAR L E A D S
SAME DIRECTION OPPOSITE DIRECTION
PROBABLE CAUSE - TIRES

SWITCH TIRES FRONT T O REAR
P R O B A B L E CAUSE - VEHICLE LEFT F R O N T T O LEFT REAR
CHECK F R O N T A L I G N M E N T LEFT REAR T O LEFT FRONT
TOE-CASTER-CAMBER RIGHT FRONT T O RIGHT REAR
RIGHT REAR TO RIGHT FRONT
I
ALIGNMENT N O T OK ROAD TEST OK
ADJUST ALIGNMENT T O
PREFERRED S E T T I N G S . I
CAR STILL LEADS
CROSS SWITCH FRONT TIRES
I
ROAD TEST OK
I
CAR STILL LEADS
SWITCH RIGHT FRONT
I
ROAD TEST OK
I
CAR STILL LEADS
LEAD CAUSED BY
LEFT FRONT
TIRE - REPLACE
9122-77
22 - 6 WHEELS AND TIRES J
WHEELS
GENERAL INFORMATION
Original equipment wheels are designed for all
loads up to the specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sec
tions between the rim flanges and the rim well.
Fig. 2 Lug Nut Tightening Pattern

• Bent or dented
• Leak air through welds
• Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
Fig. 1 Wheel Safety Rim source should be equivalent in:
• Load carrying capacity
Initial inflation of the tire forces the bead over
• Diameter
these raised sections. In case of tire failure, the
• Width
raised sections hold the tire in position on the wheel
• Offset
until the vehicle can be brought to a safe stop. • Mounting configuration
Cast aluminum wheels require special balance Failure to use equivalent replacement wheels may
weights and alignment equipment. affect the safety and handling of your vehicle. Re
placement with used wheels is not recommended.
WHEEL INSTALLATION Their service history may have included severe treat
The wheel studs and nuts are designed for specific ment.
applications. They must be replaced with equivalent Refer to the Specifications Chart for informa
parts. Do not use replacement parts of lesser quality tion regarding above requirements.
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an en WHEEL ORNAMENTATION
larged nose. This enlarged nose is necessary to en
sure proper retention of the aluminum wheels. WARNING: H A N D L E A L L W H E E L O R N A M E N T A T I O N
Before installing the wheel, be sure to remove any W I T H E X T R E M E C A R E DURING R E M O V A L AND IN
build up of corrosion on the wheel mounting surfaces. S T A L L A T I O N . S H A R P E D G E S ON T H E C O V E R S O R
Ensure wheels are installed with good metal-to-metal C A P S CAN C A U S E P E R S O N A L INJURY.
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han
dling of your vehicle. TIRE AND WHEEL BALANCE
To install the wheel, first position it properly on It is recommended that a two plane dynamic bal
the mounting surface. All wheel nuts should then be ancer be used when a wheel and tire assembly re
tightened just snug. Gradually tighten them in se quire balancing. Static should be used only when a
quence to 129 N*m (95 ft. lbs.) torque (Fig. 2). Never two plane balancer is not available.
use oil or grease on studs or nuts. For static imbalance, find location of heavy spot
causing imbalance. Counter balance wheel directly
WHEEL REPLACEMENT opposite the heavy spot. Determine weight required
Wheels must be replaced if they have: to counterbalance the area of imbalance. Place half
• Excessive runout of this weight on the inner rim flange and the other
J
half on the outer rim flange (Fig. 3, Fig. 4). Off-ve MATCH MOUNTING
hicle balancing is necessary. Wheels and tires are match mounted at the factory.
Wheel balancing can be accomplished with either This means that the high spot of the tire is matched
on or off vehicle equipment. When using on-vehicle to the low spot on the wheel rim. This technique is
balancing equipment, follow these precautions: used to reduce run-out in the wheel/tire assembly.
• Limited-slip rear axle differential, remove the op The high spot on the tire is marked with a paint
posite wheel/tire mark or a bright colored adhesive label on the out
• Before balancing the wheels/tires on a vehicle board side wall. The low spot on the rim is at the
equipped with a transfer case, disconnect the drive valve stem location on the wheel rim.
shafts Before dismounting a tire from its wheel, a refer
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is re
mounted in the original position on the wheel.
A D D BALANCE
W E I G H T S HERE
TIRE O R W H E E L TRAMP, CORRECTIVE

OR WHEEL HOP WEIGHT
LOCATION
J8922-8
Fig. 3 Static Unbalance & Balance
Fig. 4 Dynamic Unbalance & Balance

22 - 8 WHEELS AND TIRES J
(1) Measure the total indicator runout on the cen • If the high spot is within 101.6 mm (4.0 in.) of the
ter of the tire tread rib. Record the indicator reading. first spot and is still excessive, replace the tire.
Mark the tire to indicate the high spot. Place a mark • If the high spot is within 101.6 mm (4.0 in.) of the
on the tire at the valve stem location (Fig. 5). first spot on the wheel, the wheel may be out of spec
ifications. Refer to Wheel and Tire Runout.
• If the high spot is NOT within 101.6 mm (4.0 in.)
of either high spot, draw an arrow on the tread from
second high spot to first. Break down the tire and re
mount it 90 degrees on the rim in that direction (Fig.
7). This procedure will normally reduce the runout to
an acceptable amount.
2ND HIGH SPOT
ON TIRE
Fig. 5 First Measurement On Tire

(2) Break down the tire and remount it 180 de
grees on the rim (Fig. 6). SPOT ON
TIRE
VALVE S T E M
J9322-5
Fig. 7 Remount Tire 90 Degrees in Direction of

Arrow
TIRE AND WHEEL RUNOUT
Radial runout is the difference between the high
and low points on the tire or wheel (Fig. 8).
Lateral runout is the wobble of the tire or wheel.
Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
REFERENCE acceptable level, the tire can be rotated on the wheel.
MARK J9322-4 (See Method 2).
Fig. 6 Remount Tire 180 Degrees METHOD 1 (RELOCATE WHEEL ON HUB)

(3) Measure the total indicator runout again. Mark Check accuracy of the wheel mounting surface; ad
just wheel bearings.
the tire to indicate the high spot.
Drive vehicle a short distance to eliminate tire flat
(4) If runout is still excessive, the following proce
spotting from a parked position.
dures must be done.
Make sure all wheel nuts are properly torqued.
LATERAL
RUNOUT
J9022-4
J8922-11
Fig. 8 Checking Tire Runout
Relocate wheel on the mounting, two studs over Fig. 9 Checking Wheel Runout
from the original position. METHOD 2 (RELOCATE TIRE ON WHEEL)
Re-tighten wheel nuts until all are properly Rotating tire on wheel is particularly effective
torqued, to eliminate brake distortion. when there is runout in both tire and wheel.
Check radial runout. If still excessive, mark tire Remove tire from wheel and re-mount wheel on
sidewall, wheel, and stud at point of maximum hub in former position.
runout and proceed to Method 2. Check wheel radial runout (Fig. 9).
• STEEL WHEELS: Radial runout 0.040 in., Lateral
runout 0.045 in.
• ALUMINUM WHEELS: Radial runout 0.030 in.,
Lateral runout 0.035 in.
If point of greatest runout is near original chalk
mark, remount tire 180 degrees. Recheck runout.
VEHICLE VIBRATION
Vehicle vibration can be caused by: Audible vehicle vibration is heard above normal
• Tire/wheel unbalance or excessive runout background noise. The sound can be a droning or
• Defective tires with extreme tread wear drumming noise.
• Nylon overlay flat spots (performance tires only) Vibrations are sensitive to change in engine
• Incorrect wheel bearing adjustment (if applicable) torque, vehicle speed or engine speed.
• Loose or worn suspension/steering components
• Certain tire tread patterns ENGINE TORQUE SENSITIVE VIBRATION
• Incorrect drive shaft angles or excessive drive This vibration can be increased or decreased by:
shaft/yoke runout • Accelerating
• Decelerating
• Defective or worn U-joints
• Coasting
• Excessive brake rotor or drum runout
• Maintaining a constant vehicle speed
• Loose engine or transmission supports/mounts
• And by engine operated accessories VEHICLE SPEED SENSITIVE VIBRATION
Refer to the appropriate Groups in this man This vibration condition always occurs at the same
ual for additional information. vehicle speed regardless of the engine torque or en
gine speed.
VIBRATION TYPES
There are two types of vehicle vibration: ENGINE SPEED (RPM) SENSITIVE VIBRATION
• Mechanical This vibration occurs at varying engine speeds. It
• Audible. can be isolated by increasing or decreasing the en
Mechanical vehicle vibration can be felt through gine speed with the transmission in NEUTRAL posi
the seats, floor pan and/or steering wheel. tion.
22-10 WHEELS AND TIRES
VIBRATION DIAGNOSIS km/h) range. The wheel hop will not cause vibration
A vibration diagnosis should always begin with a below 20 mph (32 km/h). Wheel hop is caused by a
10 mile (16 km) trip (to warm the vehicle and tires). tire/wheel that has a radial runout of more than
Then a road test to identify the vibration. Corrective 0.045 of-an-inch (1.14 mm). If wheel runout is accept
action should not be attempted until the vibration able and combined runout cannot be reduced by re
type has been identified via a road test. positioning the tire on wheel, replace tire.
During the road test, drive the vehicle on a smooth TB—Tire/Wheel Balance: Vehicle speed sensitive,
surface. If vibration exists, note and record the fol mechanical vibration. Static tire/wheel unbalance
lowing information: will not cause vibration below 30 mph (46 km/h). Dy
• Identify the vehicle speed range when the vibra namic tire/wheel unbalance will not cause vibration
tion occurs below 40 mph (64 km/h).
• Identify the type of vibration TLR—Tire/Wheel Lateral runout: Vehicle speed
• Identify the vibration sensitivity sensitive, mechanical vibration. The runout will not
• Determine if the vibration is affected by changes cause vibration below 50 - 55 mph (80 - 88 km/h).
in vehicle speed, engine speed and engine torque. Excessive lateral runout will also cause front-end
When the vibration has been identified, refer to the shimmy.
Vibration Diagnosis chart for causes. Consider cor TW—Tire Wear: Vehicle speed sensitive, audible
recting only those causes coded in the chart that are vibration. Abnormal tire wear causes small vibration
related to the vibration condition. in the 30 - 55 mph (88 km/h) range. This will pro
Refer to the following cause codes and descriptions duce a whine noise at high speed. The whine will
for explanations when referring to the chart. change to a growl noise when the speed is reduced.
TRR—Tire and Wheel Radial Runout: Vehicle W—Tire Waddle: Vehicle speed sensitive, mechan
speed sensitive, mechanical vibration. The runout ical vibration. Irregular tire uniformity can cause
will not cause vibration below 20 mph (32 km/h). side-to-side motion during speeds up to 15 mph (24
WH—Wheel Hop: Vehicle speed sensitive, me km/h). If the motion is excessive, identify the defec
chanical vibration. The wheel hop generates rapid tive tire and replace it.
up-down movement in the steering wheel. The vibra UAJ—Universal Joint (Drive Shaft) Angles:
tion is most noticeable in the 20 - 40 mph (32 - 64 Torque/vehicle speed sensitive, mechanical/audible
VIBRATION DIAGNOSIS
C o r r e c t i o n Codes F o r Mechanical V i b r a t i o n s W i t h i n Specific M P H ( k m / h ) R a n g e s

Vibration
Sensitivity 10 20 30 A\0 f >0 60 70 80 90
(16 km) (32 km) (48 km) (64 km)
•
(80 km) (96 km)
RR and SSC
(112 km)
1
(12 8 km) (1 4 4 km)
Vehicle \ A/U l
Speed TLR
Sensitive 1 \ \ -,-.„J A k l
Torque
Sensitive ^ y IA •
U J at 1 U. A •
rc
Engine CD""
Speed ^ — E A •
Sensitive —DEM—
i — •
C o r r e c t i o n Codes F o r A u d i b l e V i b r a t i o n s W i t h i n Specific M P H ( k m / h ) R a n g e s
Vibration
Sensitivity 10 20 30 40 50 60 70 80 90
(16 km) (32 km) (48 km) (64 km) (80 km) (96 km) (112 km) (128 km) (144 km)
UJ
Vehicle
• J U and W H • —
Speed
Sensitive
Torque
Sensitive
^ UJ and T E D J - — •
Engine
Speed AC >_ •
B
Sensitive .
.,
..
..
« .
. nr
A 4
i „,
- 1 J8922-12
'1
J WHEELS AND TIRES 2 2 - 1 1
vibration. Incorrect drive shaft angles cause mechan Vehicle speed sensitive, mechanical vibration. Worn
ical vibration below 20 mph (32 km/h) and in the 70 suspension/steering components can cause mechani
mph (112 km/h) range. The incorrect angles can also cal vibration at speeds above 20 mph (32 km/h).
produce an audible vibration in the 20 - 50 mph (32 - Identify and repair or replace the defective compo
80 km/h) range. Caster adjustment could be required nents).
to correct the angles. EA—Engine Driven Accessories: Engine speed
UJ—Universal Joints: Engine torque/vehicle sensitive, mechanical/audible vibration. Vibration
speed sensitive, mechanical/audible vibration. If the can be caused by loose or broken A/C compressor, PS
U-joint is worn it will cause vibration with almost pump, water pump, generator or brackets, etc. Usu
any vehicle speed/engine torque condition. ally more noticeable when the transmission is shifted
DSY—Drive Shaft and Yokes: Vehicle speed sen into the NEUTRAL position and the engine speed
sitive, mechanical/audible vibration. The condition (rpm) increased. Inspect the engine driven accesso
will not cause vibration below 35 mph (56 km/h). Ex ries in the engine compartment. Repair/replace as
cessive runout, unbalance or dents and bends in the necessary.
shaft will cause the vibration. Identify the actual ADB—Accessory Drive Belts: Engine speed sen
cause and repair/replace as necessary. sitive, audible vibration. Worn drive belts can cause
WB—Wheel Bearings: Vehicle speed sensitive, a vibration that produces either a droning, fluttering
mechanical/audible vibration. Loose wheel bearings or rumbling noise. Inspect the drive belt(s) and tight
cause shimmy-like vibration at 35 mph (56 km/h) en/replace as necessary.
and above. Worn bearings will also produce a growl DEM—Damaged Engine or Transmission Sup
noise at low vehicle speed and a whine noise at high port Mounts: Engine speed sensitive, mechanical/
vehicle speed. The wheel bearings must be adjusted audible vibration. If a support mount is worn, noise
or replaced, as applicable. or vibration will occur. Inspect the support mounts
AN—Axle Noise: Engine torque/vehicle speed sen and repair/replace as necessary.
sitive, mechanical/audible vibration. The axle will ES—Exhaust System: Engine speed sensitive, me
not cause mechanical vibration unless the axle shaft chanical/audible vibration. If loose exhaust compo
is bent. Worn or damaged axle pinion shaft or differ nents contact the vehicle body they will cause noise
ential gears and bearings will cause noise. Replace and vibration. Inspect the exhaust system for loose,
the defective component(s) as necessary. broken and mis-aligned components and repair/re
SSC—Suspension and Steering Components: place as necessary.
SPECIFICATIONS
WHEEL LUG NUT

DISCMPf§0N fOlQWI
c
1 / 2 x 2 0 with 6 0 Cone 1 0 9 to 1 5 0 N-m
(80 to 1 1 0 ft. lbs.)
J9322-7
J BODY C O M P O N E N T S - X J VEHICLES 23 - 1
B O D Y COMPONENTS-XJ VEHICLES
CONTENTS
page page
DOORS 37 GENERAL BODY SERVICE INFORMATION .... 1

EXTERIOR COMPONENTS 3 INTERIOR COMPONENTS 93
FIXED WINDOW GLASS 75 UNDERBODY COMPONENTS 86
GENERAL BODY SER¥1CE INFORMATION

LABELS/DECALS/PLATES OFF-ROAD COMMERCIAL
Most of the labels that are affixed to the vehicles PACKAGE VEHICLE
DECAL LABEL
(Figs. 1 thru 6) contain safety or maintenance infor
mation. If a body component or glass must be re
placed, a replacement label should be installed.
Refer to the Introduction of this manual for more
information involving labels and plates.
COOLANT OIL FILTER REAR DOOR
FILL THREAD CHILD P R O T E C T I O N
LABEL I.D. L A B E L LOCK
(6-CYL. DECAL
ENGINE) REAR
FAN A N D DOOR
RADIATOR CHILD
WARNING PROTECTION
LABEL LOCK
(6-CYL. LABEL J9123-58
ENGINE)
Fig. 2 XJ Exterior Labels/Decals
BELT PRICE
S H I F T PATTERN FRENCH ENGLISH STARTING
ROUTING AND
DECAL INSTRUCTIONS
LABEL FUEL
SLEEVE
(6-CYL. ECONOMY
ENGINE) LABEL
FAN EMISSION
AND CONTROL
RADIATOR BELT MAINTENANCE
WARNING ROUTING LABEL CLOSED
LABEL LABEL BAR BODY
(4-CYL (4-CYL. CODE WIRING
ENGINE) ENGINE) LABEL J9123-59 DECAL TIRE
AIR
PRESSURE
Fig. 1 XJ Underhood & Window Glass Labels/Decals LABEL
GLOVE BOX
J9123-57
Fig. 3 XJ Interior Labels/Decals

23 - 2 BODY COMPONENTS-XJ VEHICLES J
INSTALLATION
Follow the instructions included with each replace
ment label.
KEY LOCK CYLINDERS

The ignition switch, glove box door, front doors and
liftgate all have key lock cylinders (Fig. 6). When
lock cylinder access or replacement is necessary, re
fer to the applicable service information source:
• Ignition Switch—Group 8D,
• Instrument Panel,
• Front Doors, and
• Liftgate.
IGNITION SWITCH GLOVE BOX
Fig. 4 XJ VIN Plate
REAR REAR
GLOVE BOX INSTRUMENT

KEY PANEL J9223-252
Fig. 6 Ignition Switch & Glove Box Door Key Lock

Cylinders
Fig. 5 XJ Jack Usage & Storage Instruction Labels

J BODY C O i P O N E N T S - X J VEHICLES 23 - 3
EXTERIOR COMPONENTS
BRUSH GUARD INSTALLATION
(1) Position and support brush guard on bumper.
REMOVAL Install attaching washers and nuts (Fig. 1).
(1) Remove bolts and washers that attach brush Do not tighten nuts until the brush guard is
guard (Fig. 1) to side sills. properly positioned on vehicle and aligned.
(2) Install bolts and washers to attach brush guard
to side sills (Fig. 1).
(3) Align brush guard and tighten.
GRILLE AND GRILLE OPENING PANEL (GOP)

REMOVAL
(1) Remove screws and grille (Fig. 2) from grille
opening panel (GOP).
(2) Remove screws, side marker lenses and head
lamp bezels from grille opening panel (GOP).
(3) Remove headlamps and park/turn signal lamps
from GOP (Fig. 4).
(4) Open hood.
(5) Remove nuts that attach the grille opening
panel (GOP) to the bracket on radiator support cross-
member (Fig. 2).
Fig. 1 Brush Guard Removal/Installation (6) Remove nuts that attach grille opening panel
(32 Remove nuts and washers that attach brush (GOP) to front fenders (Figs. 2 and 5).
guard to bumper. Remove brush guard from bumper. (7) Remove screws that attach the grille opening
panel (GOP) support bracket to front sill crossmem
ber (Figs. 2 and 6).
FENDER
PANEL
Fig. 2 Grille & GOP

23 - 4 10DY C O I P O N E N T S - X J WEHICLES 4
BULB SCREW GRILLE
SOCKET OPENING
PANEL
SCREW
FRAME
BULB SILL SUPPORT
J9223-72
SOCKET CROSSMEMBER BRACKET
Fig. 3 Side Marker Lamp Removal/installation Fig. 6 Crossmember-To-GOP Support Bracket

HEADLAMP SPRING ADJUSTMENT ENGINE
LAMP
SCREW TO COMPARTMENT
HARNESS
SIDE AAARKER CONNECTOR HARNESS
LAMP CONNECTOR
HEADLAMP
WIRE HARNESS
A N D CONNECTOR
P A R K / T U R N SIGNAL
LAMP BULB SOCKET
PARK/TURN T O PARK-
J9223-71 T U R N LAMP TO FOG LAMPS
SCREW S I G N A L LAMP J8923-27
Fig. 4 Headlamp & Park/Turn Signal Lamp Removal/ Fig. 7 Front Lamp Wire Harness Connectors
Installation (9) Remove grille opening panel (GOP) from vehi
cle (Fig. 2).
(10) If necessary, remove air inlet baffles from
GOP (Fig. 8).
GRILLE AIR
OPENING INLET
PANEL BAFFLE
RETAINER
GRILLE O P E N I N G - ^
PANEL J9023-10
Fig. 5 GOP Attaching Nuts At Front Fender

(8) Pull grille opening panel (GOP) forward and J9223-65
disconnect clips and all front lamp harness connec
tors (Fig. 7). Fig. 8 GOP Air Inlet Baffles
J BODY C O M P O N E N T S - X J VEHICLES 23 - i
INSTALLATION RADIATOR SUPPORT CROSSMEMBER

(1) Place grille opening panel (GOP) on bumper
and connect all front lamp wire harness connectors REMOVAL
(Fig. 7 ) . ( 1 ) Remove grille opening panel (GOP).
( 2 ) Position grille opening panel (GOP) on vehicle ( 2 ) For 2 . 5 L engines, remove power steering pump
and install side and upper nuts (Figs. 2 and 5). reservoir from left filler panel (Fig. 9 ) .
Tighten nuts with 7 N T O ( 5 8 in-lbs) torque.
RADIATOR RADIATOR NUT CAP A N D
( 3 ) Install screw to attach grille opening panel
(GOP) to crossmember support bracket (Figs. 2 and
6 ) . Tighten screw with 1 N»m ( 1 1 in-lbs) torque.
(4) Install headlamps and park/turn signal lamps
in GOP (Fig. 4).
( 5 ) Install headlamp bezels (Fig. 2 ) on GOP.
Tighten screws with 1 N»m ( 1 3 in-lbs) torque.
( 6 ) Install side marker lenses and screws (Fig. 3 )
on the grille opening panel (GOP). Tighten screws
with 1 N T H ( 1 3 in-lbs) torque.
( 7 ) Install grille on the GOP (Fig. 2 ) . Tighten
screws with 1 N * m ( 1 3 in-lbs) torque.
( 8 ) Adjust the headlamp aim, if necessary. Refer to
the headlamp beam adjustment procedure within
Group 8 L .
Fig. 9 P/S Pump Reservoir Removal/Installation
( 3 ) Remove radiator support crossmember and ra
diator from front of vehicle (Fig. 1 0 ) .
BATTERY MODULAR BATTERY HOOD SAFETY LATCH
Fig. 10 Radiator Support Crossmember & Modular Radiator

23 - 8 BODY COiPONENTS-XJ VEHICLES J
(4) If additional disassembly is required, remove RADIATOR WIRE RADIATOR FRAME SILL-TO-
horns, baffle braces and wire harnesses from baffles BAFFLE HARNESS SUPPORT BAFFLE BRACE
CONNECTOR CROSSMEMBER
(Fig. 11).
INSTALLATION
(1) If removed, install horns, baffle braces and wire HORN
harnesses on baffles (Fig. 11). BRACKET
(2) Position radiator and radiator support cross- SCREW
member at front of vehicle (Fig. - 10). Install and
tighten screws with 9 N*m (76 in-lbs) torque.
(3) For 2.5L engines, Install the power steering
pump reservoir on the left filler panel (Fig. 9).
(4) Install grille opening panel (GOP).
HORN
HOOD FRAME SILL (LO-NOTE)
The hood service procedures included in this sec WIRE HORN CROSSMEMBER WIRE
HARNESS (HI-NOTE)N^
tion include: HARNESS
CONNECTOR CONNECTOR
• hood removal and installation;
SCREW
• hood adjustment; RIGHT-SIDE H O R N LEFT-SIDE H O R N
• hinge—latch—striker service; and
TEMPERATURE
• latch release cable service. SENSOR J9223-106
Refer to Figures 12 and 16 for the hood compo
nents. Fig. 11 Horns, Baffle Braces & Wire Harnesses
BODY COMPONENTS-XJ VEHICLES 23 - 7
STRIKER V I E W
FROM RIGHT
FRONT
1. LATCH
2. BUMPER
3. CATCH
4. CLIP
5. BELLCRANK
6. ROD
7. CLIP
8. CABLE
9. GROMMET
10. S H O U L D E R BOLT
11. STRIKER
12. SHIM
13. SPRING
OF A R R O W Z
J9023-5
Fig. 12 Hood Latches, Rod, Release Cable, Striker & Safety Latch
HOOD REMOVAL HOOD HOOD STUD

SAFETY
(1) Raise hood. LATCH
s
(2) Disconnect underhood lamp wire harness con

nector (Fig. 13), if equipped.
WIRE
HARNESS
CONNECTOR
LATCH
ROD CONNECTING
LAMP J9223-79
SPRING ROD
AND
SWITCH
Fig. 15 Hood Latch & Safety Latch
HOOD , .SHIM HOOD HINGE SCREW
J9223-444
SCREW RESTRAINT
Fig. 13 Underhood Lamp

SCREW
(3) Drill heads and remove rivets that attach the
hood release cable bellcrank to hood (Fig. 14).
SEAL
HOOD RIVET DASH
INNER PANEL
PANEL
HOOD
SUPPORT
ROD
BELLCRANK
t
U-NUT
LATCH
RELEASE SUPPORT
CABLE FENDER ROD
INNER RETAINER
J9223-74 CLIP
LATCH PANEL
C O N N E C T I N G ROD J9223-68
Fig. 16 Hood Hinges & Support Rod
Fig. 14 Hood Release Cable Bellcrank (11) Remove screws that attach hinges to hood
(4) Disconnect bellcrank from latch connecting rod (Fig. 16). Remove hood from vehicle with aid of a
and release cable. Remove bellcrank from hood (Fig. helper.
14). (12) Remove insulation panel from hood (Fig. 17).
(5) Remove latch release cable clips and remove
cable from hood (Fig. 12). HOOD INSTALLATION
(6) Remove screws that attach latches to hood (Fig. (1) Install insulation panel on hood (Fig. 17).
15). (2) Position hood on shims and hinges; finger-
(7) Disconnect latches from hood and latch con tighten hinge bolts (Fig. 16).
necting rod. Remove latches from hood (Fig. 15). (3) Align hinges and shims (Fig. 16) with reference
(8) Remove nuts that attach safety latch to hood marks. Tighten hinge bolts with 30 N*m (22 ft-lbs)
(Fig. 15). Remove safety latch from hood. torque.
(9) Remove clips and latch connecting rod from (4) Connect latch release cable and latch connect
ing rod to bellcrank (Fig. 13).
hood (Fig. 15).
(5) Position bellcrank on hood (Fig. 13) and install
(10) Mark location of hood hinges and hinge shims
rivets.
(Fig. 16) for installation.
(6) Attach latch release cable to clips (Fig. 12).
BODY C O M P O N E N T S - X J VEHICLES 23 • i
(3) Adjust hood strikers (Fig. 19) with shims as

necessary. Tighten screws with 22 N*m (16 ft-lbs)
torque after adjustment.
Fig. 17 Hood Insulation Panel

(7) Connect latches to latch rod and position them
on hood (Fig. 15).
(8) Install screws to attach latches to hood (Fig. Fig. 19 Hood Latch Striker
15). (4) Align each latch and striker (Figs. 15 and 19)
Tighten screws with 9 N T H (77 in-lbs) torque. so that striker enters latch squarely.
(9) Position safety latch on hood and install attach
ing nuts (Fig. 15). Tighten screws with 13 N«m (115 HOOD HINGE REPLACEMENT
in-lbs) torque.
(10) Test latch release cable and latches for proper REMOVAL
operation. (1) Remove hood from vehicle.
(11) Connect the underhood lamp wire harness (2) Remove seal from hinge base (Fig. 20).
connector.
(12) Inspect hood for proper alignment and adjust
as necessary.
HOOD ADJUSTMENT
The hood bolt holes are elongated for fore and aft
and side-to-side adjustment.
(1) If hood is low to cowl panel, insert shims be
tween hinge and hood at rear hinge bolts.
(2) Adjust hood bumper (Fig. 18) in or out to pro
vide proper hood-to-fender height alignment.
HOOD LATCH S T R I K E R
Fig. 20 Hood Hinge & Seal

(3) Remove hinge retaining nuts from studs (Fig.
20).
(4) Remove restraint cable and hinge from cowl
panel (Fig. 20).
INSTALLATION
(1) Position hinge over studs and place restraint
cable on right, lower stud (Fig. 20).
Fig. 18 Hood Bumper

(2) Install hinge nuts on studs (Fig. 20). Tighten INSTALLATION

@
restraint cable nut with 4 N m (38 in-lbs) torque. (1) Insert replacement cable end through the hole
Tighten remaining nuts with 9 N*m (77 in-lbs) in dash panel into engine compartment.
torque. (2) Pull cable forward and seat grommet in dash
If a replacement hinge seal Is being installed, panel.
position it around the hinge arm, force it against (3) Position cable bracket on cowl side panel and
hinge base. install screws. Tighten screws with 13 N*m (111 in-
(3) Position hinge seal around hinge arm and on lbs) torque.
hinge base (Fig. 20). (4) Install left cowl side trim panel.
(4) Install hood. (5) Connect cable and latch rod to bellcrank (Fig.
(5) Adjust hood as necessary. 14).
(6) Position bellcrank on hood and install rivets.
HOOD LATCH REPLACEMENT (7) Attach cable to clips.
(8) Test release cable for proper operation.
REMOVAL
(1) Remove screw that attaches latch to hood inner SAFETY LATCH STRIKER REPLACEMENT
panel (Fig. 15).
(2) Disconnect latch from hood and latch connect REMOVAL
ing rod. Remove latch from hood (Fig. 15). (1) Remove striker screws from the radiator sup
port crossmember (Fig. 21).
INSTALLATION
(1) Connect the latch to the latch connecting rod
and position it on the hood inner panel.
(2) Install the screw that attaches the latch to the
hood inner panel.
#
(3) Tighten screw with 9 N m (77 in-lbs) torque.
(4) Test operation of latch release cable and latch.
HOOD LATCH STRIKER REPLACEMENT

REMOVE
(1) Remove grille opening panel (GOP).
(2) Remove screws that attach the striker to the
radiator baffle (Fig. 19).
(3) Remove striker and shims from baffle (Fig. 19).
INSTALLATION
Fig. 21 Hood Safety Latch Striker—2.5L Engine
(1) Position shims and striker on radiator baffle
(Typical)
and install screws (Fig. 19).
(2) Tighten screws with 21 N»m (15 ft-lbs) torque. (2) Remove striker from crossmember.
(3) Test striker/hood alignment by opening and
closing hood several times. Adjust striker, if neces INSTALLATION
sary. (1) Position striker on radiator support crossmem
ber and install screws. Tighten screws with 9 Nnn
LATCH RELEASE CABLE REPLACEMENT (77 in-lbs) torque.
(2) Test safety latch operation.
REMOVAL
(1) Drill heads and remove rivets that attach bell COWL WEATHERSTRIP SEAL/CROSSMEMBER AIR
crank to hood (Fig. 14). DEFLECTOR
(2) Disconnect bellcrank from latch rod and latch
release cable. Remove bellcrank from hood. WEATHERSTRIP SEAL REPLACEMENT
(3) Disconnect latch release cable from clips on (1) Pry upward along the length of seal (Fig. 22).
hood. (2) Detach seal retainers from cowl panel.
(4) Remove left cowl side trim panel. (3) Remove seal from cowl panel.
(5) Remove cable bracket screws from cowl side (4) Position weatherstrip seal on cowl panel. Press
panel. to insert retainers in cowl panel holes (Fig. 23).
(6) Pull cable through dash panel and remove it
from under instrument panel.
J — BODY C O M P O N E N T S - X J VEHICLES 23 - 11
DASH PANEL INSULATOR PANEL
REMOVAL
(1) Remove push-on nuts from studs (Fig. 24).
SCREW
Fig. 24 Dash Panel Insulator Panel

(2) Remove screws that attach panel to dash panel.
(3) Remove insulator panel from dash panel and
engine compartment.
INSTALLATION
(1) Position insulator panel on dash panel.
(2) Install push-on nuts on studs.
(3) Attach panel to dash panel with screws.
Tighten screws with 2 N*m (18 in-lbs) torque.
COWL GRILLE AND SCREEN

REMOVAL
(1) Use a wax pencil to mark position of wiper
arms (Fig. 25).
INSTALL W I P E R ARM
I W I T H BLADE ALIGNED
Fig. 23 Cowl Seal & Retainers

CROSSMEMBER AIR DEFLECTOR REMOVAL
(1) Remove rivets that attach air deflector to
fender flares (Fig. 22).
(2) Remove screws that attach air deflector to
crossmember.
(3) Remove air deflector from crossmember.
CROSSMEMBER AIR DEFLECTOR

INSTALLATION
(1) Position air deflector on crossmember.
(2) Attach air deflector to crossmember with GRILLE J9223-96
screws.
(3) Attach air deflector to fender flares with blind Fig. 25 Wiper Locations On Windshield
rivets. (2) Remove windshield wiper arms from pivots
(Fig. 26).
(3) Remove screws that attach grille to cowl.
12 BQm mmmmnn-m vehicles
PLASTIC SCREEN NOZZLE

W\PER BLADE WIPER SCREW
PUSH-RIVET RNET
COWL
GRILLE
SCREEN
GRILLE 19223-93
Fig. 28 Cowl Grille, Screen & Washer Nozzles

.PUSH-NUT
DASH
}9U3-W
COWL PANEL COWL
PANEL
Fig. 26 Cowl Grille Components
(3) Remove windshield washer tubes from nozzles
(Fig. 27).
NOZZLE >
GRILLE
AND
SCREEN
COWL
19223-95
PLENUM
UNDERSIDE VIEW COWL

GRILLE
Fig. 29 Cowl Grille Push-Nuts
AND SCREEN COWL GRILLE SUPPORT
PLENUM . „ BRACKET PUSH-NUT
WINDSHIELD WASHER
RU\D TUBE
FWD. COWL
PANEL 19223-92
DASH
Fig. 27 Washer Fluid Tubes PANEL
FWD 19223-94
NUT
(4) Remove cowl grille and screen from cowl (Fig.
28). Fig. 30 Cowl Grille Support Bracket
(5) If necessary, remove push-rivets and washer INSTALLATION
nozzles from cowl grille (Fig. 28).
(1) If removed, install cowl grille support bracket
(6) If necessary, remove cowl grille push-nuts from
on dash panel (Fig. 30). Tighten nuts with 9 N«m (77
cowl panel (Fig. 29).
in-lbs) torque.
(7) If necessary, remove nuts and cowl grille sup
port bracket from dash panel (Fig. 30).
J BODY COiPONENTS-XJ VEHICLES 23 - 13
(2) If removed, install push-nuts in cowl panel and NUT

SCREW-
support bracket.
UPPER
(3) If removed, install push-rivets and washer noz HOLDDOWN
zles in cowl grille. HOLDDOWN BRACKET
SUPPORT
BRACKET
CAUTION: T h e washer fluid tubes must be routed
and installed so that they are not pinched. BATTERY
SIDE
(4) Position cowl grille and screen on cowl. Install HOLDDOWN
windshield washer tubes on nozzles. ROD
(5) Install cowl screen and grille screws and RETAINER

tighten in sequence shown in Figure 31.
BATTERY
Force the cowl grille rearward while tighten TRAY
SIDE
HOLDDOWN
ing screws. ROD
RADIATOR
SCREW SUPPORT
(D?f® CD
INNER
RADIATOR FENDER
BAFFLE PANEL
J9123-164
Fig. 32 Battery Tray Removal/Installation

RETAINER
HOLDDOWN
ROD
COWL
PANEL
RETAINER
J9223-91
Fig. 31 Cowl Grille Screw Tightening Sequence

BATTERY
(6) Install windshield wiper arms on pivots. TRAY
HOLDDOWN
ROD
BATTERY TRAY
REMOVAL
(1) Remove screw, nuts, holddown support bracket
J9223-48
and upper holddown bracket from holddown rods
(Fig. 32).
Fig. 33 Battery Holddown Rods & Retainers
(2) Remove battery from tray.
(3) Remove nuts that attach battery tray to inner (6) Install holddown support bracket, screw, and
fender panel. nuts on holddown rods. Tighten screw and nuts.
(4) Remove battery tray from vehicle.
(5) If necessary, remove retainers and holddown FRONT FENDER
rods from battery tray (Fig. 33). The following information includes procedures for
removal/installation of:
INSTALLATION • a fender liner,
(1) If removed, install side holddown rods and re • a front fender flare and retainers, and
tainers on battery tray. • a front fender.
(2) Position battery tray on inner fender panel
with studs inserted in holes.
(3) Attach battery tray to inner fender panel with
nuts. Tighten the nuts with 30 N*m (22 ft-lbs)
torque.
(4) Install battery in tray.
(5) Position upper holddown bracket over holddown
rods.
23 - 14 BODY C O M P O N E N T S - X J VEHICLES
H£MO¥AL • remove the battery and tray from the fender inner
(1) Remove front bumper. panel (Figs. 36, 37 and 38);
(2) Right fender only:
• if equipped, remove radio antenna mast, and com
ponents from fender (Figs. 34 and 35);
Fig. 34 Radio Antenna Removal/Installation

POWER ANTENNA
Fig. 36 Battery, Speed Servo, PDC & Coolant
Recovery Bottle
Fig. 35 Power Antenna Wire Harness & Cable

Connectors
Fig. 37 Battery Removal/Installation

J BODY COMPONENTS-XJ VEHICLES 23 - t i
BATTERY HOOD SPEED A/C P R E S S U R E S W I T C H

TRAY AJAR S W I T C H CONTROL WIRE HARNESS
SERVO CONNECTOR
FENDER
GRILLE O P E N I N G BRACKET
PANEL MAIN WIRE
BRACKET HARNESS
SCREW
TO
BATTERY
TEMPERATURE
SENSOR
WIRE HARNESS A/C
INNER CONNECTOR RECEIVER/DRIER
FENDER
ENGINE
PANEL
WIRE
HARNESS
J9223-47
FRAME
HORN SILL CROSSMEMBER
Fig. 38 Battery Tray Removal/Installation WIRE
HARNESS
• remove windshield washer reservoir from fender CONNECTOR
inner panel (Fig. 39);
HORN TEMPERATURE
FENDER J9223-69
(HI-NOTE) SENSOR
Fig. 40 Hood Ajar Switch, Speed Servo & A/C

Receiver/Drier
SCREW PIGTAIL MAIN RIGHT
CONNECTOR WIRE FENDER
HARNESS PANEL
POWER
DISTRIBUTION
* J9223-424 •
CENTER
Fig. 39 Coolant Recovery Bottle, Windshield Washer

Fluid Reservoir & Hood Support Rod
• remove the hood ajar switch, if equipped, from
fender (Figs. 40 and 41);
Fig. 41 Hood Ajar Switch Removal/Installation
• remove the PDC, the coolant recovery bottle and
speed servo from fender inner panel.
• remove vapor canister from fender inner panel
(Figs. 42 and 45);
• remove A/C Receiver/Drier from fender inner
panel (Fig. 40); and
• if equipped, remove the Daytime Running Light
(DRL) module from fender inner panel (Fig. 46).
• support hood and remove hood support rod from
fender inner panel.
(3) Remove hood bumper from fender inner panel
(Fig. 47).
23 - 18 BODY COIPONENTS-XJ VEHICLES J
MAIN RETAINER SCREW
Fig. 42 Power Distribution Center & Vapor Canister Fig. 45 Vapor Canister
Fig. 43 Coolant Recovery Bottle Fig. 46 Daytime Running Light (DRL) Module
Fig. 44 Speed Servo Fig. 47 Hood Bumper

J BODY C O i P O N E N T S - X J VEHICLES 2 3 - 17
FENDER PUSH FENDER FENDER

FLARE PANEL INNER
PANEL v V
FENDER
PANEL
FLARE
RETAINER FENDER
LINER
NUT
F E N D E R FLARE CENTER
INSTALLED REAR FLARE
FLARE RETAINER
RETAINER
SCREW
FLARE
FENDER (REFERENCE)
FLARE
F R O N T FLARE / BLIND SPLASH
SCREW RETAINER U-NUT RIVET SHIELD J9223-495
Fig. 48 Fender Flare & Liner Removal/Installation

(4) Raise and support vehicle. • remove fender liner from between fender panels;
(5) Remove front wheel. • remove push-nuts that attach retainers to fender
(6) Remove fender liner, fender flare and retainers outer panel; and
(Fig. 48): • remove retainers and flare from fender outer
• remove screws that attach the lower part of flare panel.
to fender outer panel; (7) Remove grille opening panel (GOP).
• remove rivets that attach flare to air deflector; (8) Remove air deflector.
• remove retainers that attach fender liner to fender (9) Remove rocker panel moulding from fender.
inner panel; (10) Remove all fender braces (Fig. 49).
• remove nuts that attach fender liner to fender (11) Remove fender lower screws (Fig. 49).
outer panel and flare retainers;
HOOD
BUMPER
CROSSMEMBER
SCREW
S C R E W ^ T - ^ FILLER
Fig. 49 Fender Removal/Installation

23 - 18 BODY C O M P O N E N T S - X J VEHICLES
(12) Remove fender top, front and the rear screws. • install nuts to attach fender liner to fender and
Remove fender from inner fender panel (Fig. 49). flare retainers (Fig. 48);
• install retainers to attach fender liner to fender in
INSTALLATION ner panel;
(1) Position fender on inner fender panel. • install rivets to attach flare to air deflector (Figs.
(2) Install all of fender screws finger-tight. 48 and 50); and
(3) Install fender braces. • install screws to attach flare to the fender. Tighten
(4) Align fender with body panels and tighten the screws with 1 N*m (13 in-lbs) torque.
#
fender screws with 8.5 N m (76 in-lbs) torque.
(8) Connect front lamp wire harness connectors to
(5) Install grille opening panel (GOP).
engine wire harness connectors (Fig. 52).
(6) Install air deflector.
(7) Install fender flare and retainers (Fig. 50). LAMP ENGINE
Then install fender liner. TO HARNESS COMPARTMENT
SIDE AAARKER CONNECTOR HARNESS
LAMP CONNECTOR
PUSH-NUT CENTER FENDER T O FRAME SILL
RETAINER FLARE CROSSMEMBER AIR
DEFLECTOR
FENDER
PANEL
T O PARK-
T O FOG LAMPS
T U R N LAMP J8923-27
Fig. 52 Front Lamp Wire Harness Connectors

(9) Install front lamps.
FLARE (10) Install front bumper.
(11) Install wheel, remove the support and lower
vehicle.
(12) Right fender only: install hood support rod on
the fender inner panel.
SCREW FLARE J9223-108 (13) Install hood bumper on the fender inner
Fig. 50 Fender Flare & Retainers panel.
• position retainers and flare on fender; (14) Right fender only install the Daytime Run
• install push-nuts to attach retainers to fender; ning Light (DRL) module on fender inner panel.
• position fender liner between fender and fender in (15) Right fender only: install the A/C Receiver/
ner panel (Fig. 51); Drier on the fender inner panel.
(16) Right fender only: install the vapor canister
on the fender inner panel. Tighten the vapor canister
screws with 5 Nnn (45 in-lbs) torque.
(17) Right fender only: install PDC, coolant recov
ery bottle and speed servo on fender inner panel.
(18) Right fender only: install hood ajar switch, if
FENDER
LINER equipped. Tighten screws with 2 N»m (15 in-lbs)
torque.
CONICAL (19) Right fender only: install windshield washer
NUT
fluid reservoir on inner panel (Fig. 39).
(20) Right fender only: install battery tray and
battery on the inner panel.
CONICAL N U T (21) Right fender only: if equipped, install radio
PLASTIC
antenna. Tighten the nut/escutcheon with 4.5 N«m
BLIND SPLASH (40 in-lbs) torque. Tighten power antenna bracket
RIVET RETAINER SHIELD J9223-111
screws with 2 Nnn (20 in-lbs) torque.
Fig. 51 Fender Liner & Retainers
J BODY C O M P O N E N T S - X J VEHICLES 2 3 - 19
REAR WHEELHOUSE FLARES AND LINERS CENTER FLARE

RETAINER \
REMOVAL
(1) Remove flare and liner lower screws.
Fig. 55 Rear Wheel Opening Flare—XJ Vehicles
BODY SIDE MOULDING/CLADDING

REMOVAL
Fig. 53 Rear Wheelhouse Flare, Retainers & Liner (1) Loosen vinyl body side moulding with a heat
gun.
WHEELHOUSE
LINER SCREW J9223-496
Fig. 54 Rear Wheelhouse Liner—XJ Vehicles
(2) Remove nuts that attach liner to wheelhouse.

(3) Remove liner from wheelhouse. QUARTER PANEL
(4) Remove push-nuts that attach flare retainers to PANEL R E A R FRONT
wheelhouse. MOULDING MOULDING J9123-52
(5) Remove flare and retainers from wheelhouse.
Fig. 56 Body Side Moulding—2-Door XJ Vehicles
INSTALLATION (2) Lift edge of moulding with a putty knife and

(1) Position flare and retainers at wheelhouse. peel moulding from body panel. Apply heat to any lo
(2) Install push-nuts to attach flare retainers to cation where moulding remains adhered to a panel.
wheelhouse. (3) Remove adhesive from the body panel with 3M
(3) Position liner in wheelhouse. All Purpose Cleaner, or an equivalent cleaner.
(4) Install nuts to attach liner to wheelhouse and (4) If the original moulding will be installed, also
flare retainers. remove all adhesive from it.
(5) Install flare and liner lower screws. Tighten
screws with 1 N*m (13 in-lbs) torque. INSTALLATION
(1) Install 3M 06379 double-sided tape on the
moulding.
23 - 20 BODY COMPONENTS—XJ VEHICLES J
Ensure that the method of moulding attachment is
known (Fig. 62) before attempting removal.
FRONT FENDER MOULDINGS
(1) Pry moulding off outer fender panel.
(2) Align moulding with retainers and with clips
in fender panel. Press moulding into place on fender
panel.
FRONT DOOR MOULDINGS
FENDER
MOULDING
REMOVAL
(1) Remove screw that attaches the moulding to
FRONT door panel edge.
DOOR (2) Pry moulding off door panel.
MOULDING
INSTALLATION
QUARTER REAR
PANEL DOOR (1) Align moulding with clips in door panel. Press
MOULDING MOULDING J9123-51 moulding into place on door panel.
(2) Install screw to attach moulding to door panel
Fig. 5 7 Body Side Moulding/Cladding—4-Door XJ edge. Tighten screw with 1 N*m (9 in-lbs) torque.
Vehicles
(2) For vertical alignment, use masking tape or a QUARTER PANEL MOULDINGS
string as reference.
(3) Remove backing from tape, align moulding and
position it on body panel. (1) Pry moulding off quarter panel.
(4) Press moulding onto body panel with a roller or (2) Align moulding with clips in quarter panel
hand pressure. then press moulding into place on quarter panel.
LIFTGATE UPPER MOULDING

WOODGRAIN MOULDING
SERVICE INFORMATION REMOVAL
Woodgrain mouldings are attached to the vehicle (1) Remove the screws that attach the moulding to
outer panels by four types of fasteners (Fig. 58): the liftgate panel edge.
• tubular clips, (2) Pry moulding off liftgate panel.
• screws,
INSTALLATION
• nuts, and
• rivets. (1) Align moulding with retainer on liftgate panel.
Press moulding into place on liftgate panel.
MOULDING
MOULDING ATTACHED
(2) Install screws to attach moulding to liftgate
BODY O U T E R panel edge. Tighten screws with 1 N»m (9 in-lbs)
ATTACHED WITH
PANEL
WITH RIVET torque.
SCREW SCREW
LIFTGATE LOWER MOULDING

DOOR FENDER
OR OUTER
LIFTGATE PANEL REMOVAL
PANELS (1) Remove screw that attaches the moulding to
liftgate panel edge.
MOUDLING
(2) Remove nut that attaches inboard end of moul
ATTACHED RETAINER
WITH RIVET
ding to liftgate panel.
TUBULAR T U B U L A R CLIP (3) Pry moulding off liftgate panel.
CLIP
SCREW RIVET
T U B U L A R CLIP INSTALLATION
J9123-436
(1) Align moulding with clips in liftgate panel.
Fig. 58 Woodgrain Moulding Attaching Methods Press moulding into place on liftgate panel.
j _ _ _ _ _ BODY COMPONENTS-XJ VEHICLES 23 - 21
F R O N T FENDER FRONT LIFTGATE

F R O N T UPPER FRONT DOOR UPPER
WOODGRAIN LIFTGATE
MOULDING RETAINER DOOR UPPER MOULDING
OVERLAY
UPPER MOULDING
MOULDING SCREW
SCREW
TUBULAR
REAR QUARTER
CLIP
DOOR PANEL
QUARTER
FRONT LOWER UPPER SCREW
IRONT FRONT PANEL LIFTGATE
FENDER MOULDING MOULDING
FENDER DOOR LOWER LOWER
FRONT REAR LOWER MOUDLING MOUDLING
LOWER LOWER MOULDING
MOULDING MOULDING
J9123-435
Fig. 59 Woodgrain Moulding—XJ

LICENSE PLATE SURROUND MOULDING
UFTGATE UFTGATE UFTGATE
INNER OUTER
PANEL PANEL REMOVAL
(1) Remove screw that attaches upper end of moul
ding.
LIFTGATE
PAN UFTGATE
HEAD OUTER PANEL
SCREWjY
FLANGED OVERLAY
HEX MOLDING
SCREW
NUT
NUT SCREW
OVAL-
HEAD -
SCREW
TUBULAR
CLIP
OUTER
LIFTGATE
PANEL MOLDING
OUTER LIFTGATE
PANEL J9223-10 OUTER
PANEL
Fig. 60 Liftgate Mouldings—XJ
(2) Install screw and nut to attach ends of mould
ing. Tighten screw with 1 N»m (9 in-lbs) torque. J t ~ \
lUBULAR OVER
Tighten nut with 3 N«m (27 in-lbs) torque. J9223-9 CLIP
Fig. 61 License Plate Surround Moulding—XJ

(2) Remove nut that attaches inboard end of moul Whenever an overlay must be stretched, do not
ding. slit or cut It, Instead, apply heat and press or
squeegee overlay Into place.
(3) Pry moulding off liftgate panel.
INSTALLATION REQUIREMENTS
INSTALLATION Overlay replacement requires that metal repair
(1) Align moulding with clip in liftgate panel. and paint refinish be completed before overlay is in
Press moulding into place. stalled.
(2) Install the screw and nut to attach the ends of The work area temperature should be between
the moulding. Tighten screw with 1 N»m (9 in-lbs) 18°C (65°F) and 32°C (90°F). A woodgrain overlay
torque. Tighten nut with 3 N m (27 in-lbs) torque.
#
should not be replaced if the work area temper

LICENSE PLATE VISOR APPLIQUE ature is less than 18°C (65°F).
The following equipment and material are neces
REMOVAL sary for overlay installation:
(1) Drill heads and remove rivets that attach out • a commercial woodgrain overlay removal solution;
board ends of applique to tailgate. • a commercial adhesive removal solution;
• liquid dish detergent (for wetting solution);
• a mixture of wetting solution;
• a commercial wax and silicone removal solution;
• isopropyl alcohol (rubbing alcohol);
• a squeegee ( 4 to 5 inches wide, plastic or hard rub
ber);
• a water bucket and sponge;
• sandpaper (no. 3 6 0 or no. 4 0 0 , wet or dry type);
• a heat gun (or infra-red heat bulb);
• clean wiping rags or paper towels;
• a pair of scissors;
• a needle or pin; and
• a wax pencil.
Using a wetting solution helps installation of an
overlay. Prepare a solution by mixing two or three
teaspoons of dish detergent with 1 gallon of water.
Fig. 62 License Plate Visor Applique Do not use soap.
Too much detergent will reduce effectiveness
(2) Carefully pry applique off license plate visor of mixture.
and tailgate (Fig. 62).
OVERLA Y REMOVAL
INSTALLATION (1) Remove adjacent moulding from panel.
(1) Align moulding with visor and then press ap ( 2 ) Start at one corner and apply heat with a heat
plique into place. gun. Slowly peel overlay from panel (Fig. 6 3 ) .
(2) Install rivets to attach outboard of applique to
tailgate. WARNING: U S E T H E WOODGRAIN O V E R L A Y AND
A D H E S I V E R E M O V A L S O L U T I O N S IN A W E L L - V E N
WOODGRAIN OVERLAY T I L A T E D A R E A ONLY.
SERVICE INFORMATION
( 3 ) A commercial solution can be used for overlay
Exterior woodgrain overlay is a weather-resistant removal where heat gun is ineffective.
vinyl. The adhesive backing is protected by a paper ( 4 ) Remove any adhesive remaining with a com
liner until removed for installation. mercial solution.
( 5 ) Wipe panel with a cloth saturated with a clean
OVERLAY REPAIR
ing solution.
Small nicks and scratches on an overlay can be
touched-up with paint. OVERLAY INSTALLATION
To eliminate blisters and air bubbles, pierce them The panel area that will be covered by woodgrain
with a needle or pin. Force the trapped air out of the overlay must be scuff sanded and then cleaned with
hole and press firmly against the body. Heat also can a cleaning solution.
be applied to remove small wrinkles.
10DY COMPONENTS-XJ VEHICLES 2 3 - 23
• cut overlay to approximate size with scissors.

(2) Place overlay on a clean, flat surface with pa
per liner facing upward.
(3) Bend corner of overlay toward the woodgrain
side and, with a flick of the finger, separate paper
liner from overlay.
OVERLAY APPLICATION
(1) Use a clean sponge and apply wetting solution
to overlay adhesive and to painted panel surface.
(2) Position adhesive side of overlay on panel.
(3) Apply solution to woodgrain side of overlay.
(4) For a complete, or a large section of overlay,
following method should be used:
® position a squeegee at the center and slide it
across a short horizontal area of overlay;
• lift right or left edge of overlay, align it with
panel. Slide squeegee toward the lifted edge with
firm, strokes;
• avoid stretching overlay at its lifted edge;
• continue until all of air bubbles and wetting solu
tion are removed from underside of overlay.
Fig, 63 Woodgrain Overlay Removal If a wrinkle is trapped in overlay,stop immedi
ately. Lift wrinkled area and re-align to remove
FENDER REAR QUARTER FUEL wrinkle. Do not lift overlay if only a few air bub
bles exist.
(5) Notch corner and curved edges of overlay and
trim excess.
(6) Allow 12 mm (1/2 in) extra overlay to extend
beyond edges.
CAUTION: Use extreme care to avoid spilling iso-

propyl (rubbing) alcohol on the moulding or painted
surfaces. Wipe spills immediately.
(7) Wipe adhesive side of edges with isopropyl al

cohol.
(8) Heat overlay edges with a heat gun to soften
J9123-474 OVERLAY OVERLAY RETAINER and make them more pliable.
( 9 ) Fold edges over onto panel flange area and
Fig. 64 Woodgrain Overlay—MJ Vehicles press into place with your fingers. Alternately heat
and press edge until it is bonded to flange area.
SURFACE PREPARAT10I
(10) Carefully cut away excess from panel open
(1) Scuff-sand the painted surface with no. 360 or ings with a knife.
400 sandpaper. Freshly painted surfaces must be (11) Inspect overlay. Remove all air and moisture
dry. bubbles with a needle or pin.
(2) Clean the painted surface with a commercial (12) Install all removed components and clean ve
wax and silicone removal solution. Wipe surface with hicle as necessary.
a clean cloth and allow it to dry.
FRONT FENDER OVERLAY APPLICATION
OVERLAY PREPARATI01 Install a complete front fender overlay according to
(1) If a complete panel overlay is not to be in the following instructions.
stalled, position overlay on panel surface to be cov (1) Position top edge of front fender overlay at
ered: character line and rear edge at panel welds.
• mark approximate outline on overlay with a wax (2) Wipe adhesive side of fender overlay edges with
pencil; isopropyl alcohol.
• ensure that 12 mm (1/2 in) excess is allowed to be (3) Heat fender overlay edges with a heat gun to
wrapped around door and fender flanges; and soften and make them more pliable.
23 - 24 BODY COMPONENTS ~XJ VEHICLES J
CAUTION: Avoid unnecessary pulling and stretch FRONT DOOR UPPER UPPER
ing at the ends. OVERLAY HINGE HINGE
(4) Fold edges over onto fender panel flange and RETAINER
RETAINER
press them into place with your finger tips.
REAR
FRONT FENDER
A-PILLAR DOOR
FENDER UPPER
OVERLAY
OVERLAY* MOULDING
RIVET RIVET
FUEL
FILLER HINGE
DOOR
OVERLAY
RIGHT REAR D O O R
RIGHT F R O N T D O O R
J9123-475
FENDER
LOWERS Fig. 66 Overlay Retainer At Door Front Flange
REAR
FUEL FILLER P O O R REAR FRONT DOOR
MOULDING
INSIDE VIEW DOOR DOOR INNER
LEFT F R O N T FENDER EDGE EDGE PANEL
J9123-476
GUARD GUARD
Fig. 65 Woodgrain Overlay Installation

(5) Install fender moulding.
DOOR OVERLA Y APPUCMTION

Install a complete front or rear door overlay accord
ing to the following instructions.
(1) Position top edge of the door overlay at charac DOOR
ter line and front edge at panel welds. OUTER
(2) Wipe adhesive side of door overlay edges with PANEL
TRIM EXCESS DOOR
isopropyl alcohol. OVERLAY AFTER OUTER
(3) Heat the door overlay edges with a heat gun to INSTALLATION (IF APPLICABLE) PANEL
soften and make them more pliable. DOOR
INNER
CAUTION: Avoid unnecessary pulling and stretch PANEL
ing at the ends.
DOOR DOOR
(4) Fold edges over onto door panel flange areas EDGE OUTER
GUARD PANEL J9123-60
and press them into place with your finger tips.
(5) Install overlay retainer at door front flange Fig. 67 Door Edge Guards
with rivets (Fig. 66).
(6) Install door edge guard (Fig. 67). (5) Install overlay retainer at the rear door open
(7) Install door moulding. ing with rivets.
(6) Cut an opening in the overlay for the fuel filler
QUARTER PANEL OVERLAY APPLICATION opening.
(1) Position top edge of quarter panel overlay at (7) Install overlay retainer at fuel filler opening
character line and rear edge at panel welds. with rivets.
(2) Wipe adhesive side of quarter panel overlay (8) Install quarter panel moulding.
edges with isopropyl alcohol.
(3) Heat quarter panel overlay edges with a heat FUEL FILLER DOOR OVERLAY APPLICATION
gun to soften and make them more pliable. (1) Clean door flange with an appropriate solution.
(2) Position top edge of overlay at character line
CAUTION: Avoid unnecessary pulling and stretch and notches at door edge.
ing at ends. (3) Wipe the adhesive side of fuel filler door over
(4) Firmly fold edges over onto quarter panel lay edges with isopropyl alcohol.
flange areas and press them into place with your fin (4) Heat door overlay edges with a heat gun to
ger tips. soften and make them more pliable.
j BODY G O M P O N E N T S - X J VEHICLES 23 - 25
LIFTGATE
J9223-7
Fig. 68 Rear Door Opening Overlay Retainer Fig. 70 Liftgate Overlay Side Retainers
BODY STRIPES/DECALS
SERVICE INFORMATION
XJ body stripes and decals are weather resistant
tape with a adhesive backing.
REPAIR
Small nicks, scratches and other surface marks in
a body stripe/decal can be touched-up with paint.
To eliminate blisters and air bubbles in a body
stripe/decal, pierce them with a needle or pin.
A heat gun can also be used to remove small wrin
kles in a stripe/decal.
REQUIREMENTS
Body stripe/decal replacement requires that the
Fig. 69 Fuel Filler Opening Overlay Retainer metal repair and paint refinish be completed first.
The work area temperature should be between
CAUTION: Avoid unnecessary polling and stretch
18°C (65°F) and 32°C (90°F). A tape stripe/decal
ing at the ends. should not be replaced if the work area temper
ature is less than 18°C (65°F).
(5) Fold overlay edges over onto door panel flange
areas. Press them into place with your finger tips. The following equipment and material are neces
sary for removal and installation:
LIFTGATE OVERLAY APPLICATION • a commercial tape stripe/decal removal solution;
(1) Position top edge of overlay at character line • a commercial adhesive removal solution;
and inner edges at license plate recess. • liquid dish detergent (for the wetting solution);
(2) Wipe adhesive side of liftgate overlay edges • a mixture of wetting solution;
with isopropyl alcohol. • a commercial wax and silicone removal solution;
• isopropyl (rubbing) alcohol;
(3) Heat liftgate overlay edges with a heat gun to
• a small squeegee (plastic or hard rubber);
soften and make them more pliable.
• a water bucket and sponge;
CAUTION: Avoid unnecessary pulling and stretch • clean wiping rags or paper towels;
ing at the ends. • a heat gun (or infra-red heat bulb);
• a wax pencil;
(4) Fold overlay edges over onto liftgate panel • a sharp knife, single edge razor blade or X-acto
flange and press into place with your finger tips. knife;
(6) Install liftgate moulding. • a pair of scissors; and
(7) Install license plate visor applique. • a needle or pin.
The Use of a wetting solution aids the installation
of a tape stripe/decal on a painted panel. Prepare a
23 - 26 BODY COMPONENTS-XJ VEHICLES
supply of wetting solution by mixing two or three

teaspoons of dish detergent with 1 gallon of water.
Do not use soap.
Too much detergent will reduce the effective
ness of the mixture.
REMOVAL
(1) Clean repaired surface, adjacent panels and
door openings as necessary.
(2) Start at one end of tape stripe/decal and apply
heat with a heat gun. Slowly peel the stripe/decal
from the panel by pulling it back. Do not pull the
tape stripe/decal outward from panel.
WARNING; U S E T A P E S T R I P E / D E C A L REMOVAL TAPE RESIDUE

J9123-585 STRIPF ADHESIVE
S O L U T I O N IN A W E L L - V E N T I L A T E D A R E A ONLY.
Fig. 72 Body Stripe/Decal Removal
(3) A tape stripe/decal removal solution can be
used for removal at areas where a heat gun is inef TAPE
fective: STRIPE
• Mask-off the body panel area surrounding the tape

stripe/decal (Fig. 71);
MASK
RESIDUE
J9123-586 ADHESIVE
Fig. 73 Body Stripe/Decal Removal With A

Squeegee
TAPE S T R I P E MASKING
TAPE
panel for 3 to 5 minutes only.
J9123-584 REMOVER MASK
(5) After 3 to 5 minutes, use a squeegee to remove
Fig. 71 Stripe/Decal Removal Solution Application adhesive (Fig. 74).
• move solution spray across complete length of " " SQUEEGEE
stripe/decal with a steady motion;
• ensure that complete stripe/decal is covered with
solution;
• allow stripe/decal removal solution to remain on
stripe/decal for 20 minutes;
• after 20 minutes, peel stripe/decal away from
flange area;
• if there is difficulty with peeling stripe/decal away
from body panel, use a squeegee (Fig. 73).
• with stripe/decal removed, scrape all the stripe/de
cal solution from panel surface before proceeding.
WARNING: U S E T H E A D H E S I V E REMOVAL S O L U
TION IN A W E L L - V E N T I L A T E D A R E A ONLY. RESIDUE
ADHESIVE J9123-587
(4) After stripe/decal is removed, remove any adhe Fig. 74 Adhesive Removal With A Squeegee
sive remaining with a removal solution.
Allow adhesive removal solution to remain on (6) Remove masking tape and mask from panel.
J BODY COiPONENTS-XJ VEHICLES 23 - 27
(7) Wipe panel with a cloth saturated with a adhe M A S K I N G TAPE

sive cleaning solution.
BODY PANEL SURFACE PREPARATION

(1) The area that will be covered by the tape
stripe/decal must be cleaned with cleaning solution.
(2) Freshly painted surfaces must be thoroughly
dry.
(3) Clean painted surface with a commercial wax
and silicone removal solution. Wipe surface with a
clean cloth and allow it to dry.
REPLACEMENT ON ONE PANEL TAPE S T R I P E

For tape stripes/decals, use a clean sponge and ap CARRIER
BODY
ply wetting solution: PANEL J9123-589
• to the adhesive side of the tape stripe/decal, and
• to the painted panel surface. Fig. 76 Tape Stripe/Decal & Carrier Retained On
The wetting solution will permit ease of tape Body Panel
stripe/decal movement when positioning it. TAPE STRIPE
(1) Align a straight edge with existing tape stripe/ CARRIER
decal ends (Fig. 75).

STRAIGHT GREASE
EDGE PENCIL
BODY
PANEL J9123-590
Fig. 77 Tape Stripe/Decal & Carrier Reversed On

BODY Body Panel
PANEL J9123-588
(6) Bend a corner of carrier outward and then,
Fig. 75 Stripe/Decal Alignment Reference Mark with a flick of the finger, separate corner of carrier
If applicable, the body panel character line from decal.
can be used as the tape stripe/decal alignment (7) Separate approximately 15 cm (6 in) of the car
reference. rier from one end of tape stripe/decal.
(2) Position tape stripe/decal and carrier on body (8) Return tape stripe/decal back to its original po
panel and mark length with a wax pencil. sition. If a solution is being used, position adhesive
(3) Cut stripe/decal and carrier at required length side of tape stripe/decal on panel. Apply solution to
with scissors. outside of tape stripe/decal.
(4) Position stripe/decal and carrier on the body (9) Hold tape stripe/decal against the panel surface
panel and hold it in-place with pieces of masking while separating carrier from stripe/decal.
tape (Fig. 76). (10) Where applicable, extend tape stripe/decal 12
(5) Lift bottom edge of tape stripe/decal and car mm (1/2 in) beyond door edge. Wrap it around on the
rier. Use tape sections as hinges, and reverse posi flange and press it to door flange.
tion of stripe/decal and carrier. (11) If applicable, remove cover from face of tape
stripe/decal.
CAUTION: Always remove carrier from tape stripe/ (12) Inspect tape stripe/decal with reflected light to
decal, never remove tape stripe/decal from carrier find any damage. Remove all air and/or moisture
bubbles.
23 - 28 BODY COMPOIENTS-XJ VEHICLES J
CARRIERS
TAPE
STRIPE COWL
TAPE
STRIPE
HOOD
TAPE HOOD GOP HOOD
STRIPE TAPE TAPE TAPE
STRIPE STRIPE STRIPE
FENDER FRONT REAR QUARTER LIFTGATE

TAPE DOOR DOOR PANEL TAPE STRIPE
STRIPE TAPE TAPE TAPE STRIPE
BODY STRIPE STRIPE J9223-233
PANEL J9123-591
Fig. 78 Tape Stripe/Decal & Carrier Separated Fig. 81 Tape Stripes—XJ
TAPE S T R I P E
REAR DOOR
QUARTER UPPER TAPE
PANEL STRIPE FRONT DOOR
UPPER UPPER TAPE DOOR LOWER
FENDER TAPE STRIPE
TAPE STRIPE STRIPE
UPPER
TAPE
STRIPE
SQUEEGEE
BODY
PANEL
QUARTER FENDER
CARRIER J9123-592 ARGENT
PANEL FRONT LOWER
PAINT
LOWER REAR DOOR TAPE
Fig. 79 Tape Stripe/Decal Installation REAR STRIPE
TAPE STRIPE LOWER
DOOR
TAPE
LOWER
STRIPE
TAPE
STRIPE
J9223-14
Fig. 82 Upper & Lower Body Side Tape Stripes—XJ

Vehicles
(1) Place tape stripe/decal on a clean, flat surface
with carrier side facing upward.
CAUTION: Always remove carrier from tape stripe/

decal, never remove tape stripe/decal from the car
TAPE
DOOR STRIPE
rier.
FACE
(2) Bend a corner of the carrier inward and then,
FLANGE J9123-593 with a flick of the finger, separate corner of carrier
from tape stripe/decal.
Fig. 80 Tape Stripe/Decal Installation On Door
( 3 ) Retain tape stripe/decal firmly against flat sur
Flange
face and separate carrier from tape stripe/decal.
COMPLETE REPLACEMENT (4) Use a sponge and apply solution to tape stripe/
The following procedure will simplify installation decal adhesive and to panel surface.
of a complete or very large section. (5) Position adhesive side of tape stripe/decal on
panel with bottom aligned with character line.
J BODY COMPONENTS-XJ VEHICLES 23 - 29
LIFTGATE FRONT
DECAL LOCATION FENDER
J9223-41
J9223-11
Fig. 83 Hood Tape Stripes—XJ Vehicles Fig. 85 Tape Stripes & Decal—XJ Sport
(8) Slide a squeegee from the center to the ends of
the tape stripe/decal. Use firm strokes to remove all
of the air bubbles.
(9) If a wrinkle is trapped in the tape stripe/decal
stop immediately. Lift wrinkled area and re-align
with character line to remove wrinkle. Do not lift
tape stripe/decal if only a few air bubbles exist.
(10) Where applicable, allow 12 mm (1/2 in) extra
tape stripe/decal to extend beyond edges.
(11) Fold excess tape onto the inside flange and ad
here it with finger pressure.
(12) Inspect tape stripe/decal installation with re
flected light to find any damage.
(13) Remove all air and moisture bubbles from
tape stripe/decal with a needle or pin.
(14) Install any removed components and clean ve
hicle as necessary.
ALIGN W I T H CHARACTER LINE

QUARTER WINDOW A P P L I Q U E - X J VEHICLES
J9223-12 REMOVAUINSTALLA TION
(1) Remove nuts from inside vehicle.
Fig. 84 Tailgate Tape Stripes—XJ Vehicles (2) Carefully pry applique from panel.
• align end of the replacement tape stripe/decal with (3) Position replacement applique on panel and in
end of existing tape stripe/decal, and stall nuts.
• correctly align index darts and index notches.
(6) If a complete replacement tape stripe/decal is DRIP RAIL MOULDING-XJ VEHICLES
not being installed: REMOVAL
• position replacement tape stripe/decal section at
(1) Pry clips from roof flange.
center of the repair area,
(2) Remove clips and moulding from roof flange.
• align it with existing tape stripe/decal, and
(3) Remove remaining sealant and clean roof
• allow at least 12 mm (1/2 in) of tape stripe/decal
flange.
section to overlap tape stripe/decal edges.
(7) Apply wetting solution to outer side of tape INSTALLATION
stripe/decal. (1) Position drip rail moulding with clips at roof
flange and force clips onto roof flange.
CAUTION: Avoid u n n e c e s s a r y pulling and stretch
(2) Apply sealant to inner side of moulding to seal
ing at t h e e n d s .
roof flange.
23 - 3 0 I O D Y C O i P O N E N T S - X J VEHICLES J
VEHICLE DRIP DRIP DRIP EXTERIOR NAMEPLATES
SERVICE INFORMATION
All of nameplates, with the exception of the JEEP
nameplate located on the grille are attached with ad
hesive.
Fig. 86 Quarter Window Applique & Drip Moulding Fig. 88 XJ Exterior Nameplates
AIR EXHAUST G R I L L E - X J VEHICLES GRILLE OPENING PANEL NAMEPLATE
REMOVAL REMOVAL
(1) Remove screw that attaches the grille to door (1) Remove grille opening panel (GOP) support
opening panel (Fig. 87). bracket.
(2) As applicable, remove nut(s) from letter(s) that
must be replaced.
(3) Remove nameplate letter(s) from GOP.
INSTALLATION
(1) Clean panel surface.
(2) Position replacement letter(s) on the GOP.
(3) Install nut(s) and tighten.
ADHESIVE-RACKED NAMEPLATES
(1) Pry nameplate from vehicle panel.
(2) Clean panel surface.
(3) Position replacement nameplate on panel push
inward to seat it.
Fig. 87 Door Opening Air Exhaust Grille
FUEL FILLER NOZZLE/TUBE
(2) Pry bottom edge of grille from door opening
panel. REMOVAL
(3) Pull downward and remove grille from exhaust (1) Remove fuel filler door from quarter panel (Fig.
port in door opening panel. 89).
(2) For XJ vehicles, remove fuel filler hose splash
INSTALLATION shield from quarter inner panel and frame rail (Fig.
(1) Position slot located in upper end of replace 89).
ment grille at exhaust port and insert edge in slot. (3) Remove cap from nozzle.
(2) Push inward and seat grille in exhaust port. (3) Loosen clamps and separate hoses from tubes.
(3) Install screw to attach grille to door opening (4) Remove screws that attach nozzle to housing.
panel. (5) Remove nozzle/tube from fuel filler housing.
J BODY C O M P O N E N T S - X J VEHICLES 23 - 3 1
F U E L FILLER DOOR
HINGE
NOZZLE/TUBE
HOUSING
BRACKET
TOR*
HEAD
SCREW
DOOR
VENT
QUARTER PANEL SCREW TUBE TUBE
J9223-195 J9223-193
Fig. 89 Fuel Filler Door—Typical Fig. 92 Fuel Filler Nozzle/Tube

Removal/Installation—XJ Vehicles
FILLER
TUBE (3) Attach hoses to tubes with clamps. Tighten
QUARTER
clamp screws with 4 N»m (35 in-lbs) torque.
VENT (4) Install cap on nozzle.
TUBE PANEL
(5) For XJ vehicles, install fuel filler hose splash
shield on quarter inner panel and frame rail.
(6) Install fuel filler door on quarter panel.
FUEL FILLER DOOR BUMPERS

FRAME REPLACEMENT
RAIL
(1) Grasp bumper with pliers and pull outward to
remove from the hole.
SPLASH QUARTER DOOR
SCREW SHIELD J9223-194 PANEL BUMPER
Fig. 90 Fuel Filler Hose Splash Shield—XJ Vehicles

CAP. FILLER
NOZZLE/TUBE
HOUSING
SCREW
DOOR
DOOR-STOP QUARTER HINGE
J9223-199 BUMPER PANEL
FUEL
VENT HOSE
HOSE Fig. 93 Fuel Filler Door Bumpers
It could possibly be necessary to remove door
CLAMP J9223-192 to replace door-stop bumper.
(2) Insert bumpers in the holes and force inward
Fig. 91 Fuel Filler Nozzle/Tuhe—XJ Vehicles until seated in holes.
INSTALLATION
(1) Insert fuel filler nozzle/tube into housing. EXTERNAL MIRRORS
(2) Install screws to attach the nozzle/tube to the
SERVICE INFORMATION
housing. Tighten screws with 2 N*m ( 2 0 in-lbs)
Service procedures for all external rear view mir
torque.
rors are below.
Fig. 94 Fuel Filler Door-Stop Bumper

REMOTE AND POWER/MANUAL MIRRORS
J8923-46
REMOVAL
(1) Remove door trim panel. Fig. 96 Remote Mirror Toggle Control Set Screw
(2) Remove mirror inside trim cover screw.
SCREW GROMMET
GROMMET SCREW SCREW J9123-135

Fig. 97 Trim Covers Without External Mirror
Fig. 95 Remote & Power/Manual Mirrors
(6) Install door trim panel.
(3) For power/manual mirrors, remove the inside
trim cover. WIDE-VIEW MIRROR
(4) For remote control mirrors, loosen toggle con
trol setscrew. REMOVAL
(5) For remote control mirrors, remove inside trim (1) Remove mirror base cover.
cover. (2) Remove mirror base screws.
(6) Remove mirror screws. The mirror base reinforcement is attached to
(7) Remove mirror from door. Refer to Group inside of door panel with rivets.
8—Electrical. (3) Remove mirror from door panel.
INSTALLATION INSTALLATION
(1) Position mirror adjacent to vent window. (1) Clean door panel-mirror base contact surface.
(2) Install mirror screws. Tighten screws securely. (2) Position mirror base on door panel.
(3) For remote mirrors, position inside trim cover (3) Install and tighten mirror base screws.
over toggle control and tighten setscrew. (4) Install mirror base cover.
(4) Install inside trim cover.
(5) Install inside trim cover screw.
DISENGAGEMENT/
ENGAGEMENT
MIRROR
LEVERS
BASE
COVER
SEAL
REINFORCEMENT
DOOR
J9123-136
Fig. 98 Wide-View Exterior Mirror PLATE
SUNROOF-XJ VEHICLES HANDLE

(OPEN/CLOSE) J9223-494
SERVICE INFORMATION
The following procedures can be used to either re F i g . 100 Glass Disengagement/Engagement
pair or replace a pop-up sunroof installed in a XJ GLASS
vehicle.
FRAME UPPER
A N D GLASS DRAIN
TUBE
ADJUSTER
PLATE
RETAINER
ADJUSTER J8901-23
LOWER
DRAIN
TUBE
Fig. 101 Safety Latch
J8901-21
(5) Press firmly inward on both of the glass hinge-
F i g . 99 Sunroof (Exploded View) halves to release them from hinge pivots. Remove
DISASSEMBLY glass and store it in a safe place.
(1) Turn handle and completely open glass. (6) Hold handle to prevent it from turning and re
(2) Push red disengagement levers inward, push move screw.
upward on glass to disengage it from adjuster and re (7) Remove screws that attach the top plate to ad
lease levers. juster.
(3) Continue pushing upward on glass until safety (8) Remove screws that attach the adjuster to sun
latch contacts top plate. roof frame and remove adjuster.
(4) Release safety latch and tilt glass upward and (9) If it is necessary to remove sunroof frame from
away from frame (Fig. 101). roof panel:
23 - 34 BODY COMPONENTS—XJ VEHICLES j
ADJUSTER T O P PLATE
HINGE
J8901-24
Fig. 102 Hinge Separation

Fig. 105 Adjuster Removal/Installation
• pull rubber seal away from headliner; and
• remove headliner to expose retainer screws.
ROOF FRAME FRAME FLANGE
Fig. 103 Handle & Screw

HEADLINER SCREW SEAL J9223-87
Fig. 106 Flange Seal Removal/Installation

(10) Loosen clamp and disconnect upper drain
tubes from lower drain tubes. Remove screws and re
tainers.
(11) Remove screws that attach the reinforcement
to frame. Cut the seal with a hot knife or wire, and
remove reinforcement.
(12) Pull lower drain tubes up through roof rail
and A-pillars.
(13) Remove sunroof frame from roof panel.
(14) Remove sealant from frame and roof panel.
J9223-82 ASSEMBLY
(1) Apply sealant around perimeter of roof panel
Fig. 104 Handle & Plate Removal/Installation opening.
J BODY COMPONENTS-XJ VEHICLES 23 - 3S
ROOF I N N E R CLAMP UPPER 6-MM (0.25-IN.) DIAMETER BEAD

S I D E RAIL DRAIN OF POLYURETHANE SEALANT
TUBE
REINFORCEMENT
BRACKET
LOWER J9223-84
DRAIN TUBE J9101-4
Fig. 109 Seaiant Application On Reinforcement
Fig. 107 Drain Tubes
Bracket
FRAME
UPPER SUNROOF REINFORCEMENT
DRAIN BRACKET
TUBE
(RIGHT SIDE)
UPPER
DRAIN
LOWER LOWER TUBE
DRAIN DRAIN (LEFT SIDE)
TUBE ROOF TUBE
REINFORCEMENT
(RIGHT SIDE) PANEL (LEFT SIDE) J9223-86
Fig. 110 Sunroof Frame Installation

ROOF HINGE-HALF FLANGE HINGE-HALF
LOWER PANEL (FRAME) SEAL (GLASS)
DRAIN
RETAINER TUBE JW01-28
Fig. 108 Retainers & Frame Removal/Installation GLASS

(2) Apply sealant to adjuster plate reinforcement
bracket.
(3) Position sunroof frame in roof panel opening.
(3) Insert and guide lower drain tubes through the FRAME SEAL RUBBER
SEAL
roof rail and down A-pillars.
(4) Attach reinforcement bracket to frame with
screws. Install upper drain tubes and connect them
to lower drain tubes.
(5) Position retainers against roof panel and frame INSTALLATION
J9223-83
RETAINER SCREW FRAME ROPE
and install screws.
(6) Install headliner. Fig. 111 Sunroof Seal & Installation Rope
(7) Place headliner installation rope in the rubber (10) Position top plate on adjuster and install screws.
seal recess and route it around seal. (11) Position handle on adjuster, hold it to prevent
(8) Pull rope downward and install lip of rubber it from turning and install screw.
seal around headliner opening. (12) Position glass so hinge-halves mate. Join
(9) Position adjuster on sunroof frame and install hinge-halves at pivots. Lower glass.
screws.
23 - 38 BODY C O M P O N E N T S - X J VEHICLES J
RUBBER ROOF CROSS RAIL CROSS RAIL
Fig. 112 Sunroof Seal Installation Fig. 114 Luggage Rack—XJ Vehicles
(13) Release safety latch, lower glass to top plate The skid strips are attached to roof panel with
and engage safety latch. adhesive.
(14) Push red engagement levers inward, push down (3) Loosen each skid strip with a heat gun.
ward on glass to engage it with adjuster, and release le (4) Lift one edge of each skid strip with a putty
vers. knife and peel it from roof panel.
(15) Turn handle and completely close glass. (5) Remove original adhesive from roof with an ad
hesive removal solution.
SUNROOF GLASS STORAGE BAG FOOTMAN LOOP (6) If the original skid strips are installed, remove
REMOVAL all original adhesive from them.
(1) Drill rivet head and remove rivet from footman
INSTALLATION
loop and floor panel.
(1) Install 3M 06379 double-sided tape on skid strips.
(2) Remove backing from double-sided tape, align
each skid strip on roof, and position it on roof panel.
(3) Verify that each skid strip is properly aligned.
ROOF SKID
Fig. 113 Footman Loop Removal/Installation

(2) Remove footman loop from cargo area.
J9223-98
INSTALLATION Fig. 115 Skid Strip Installation

(1) Position footman loop over rivet hole.
(2) Attach footman loop to floor panel with a blind (4) Press each skid strip onto roof panel with a
rivet. roller (or use hand pressure).
To prevent water leaks, apply 3M Drip-Chek
LUGGAGE R A C K - X J VEHICLES Sealant (or an equivalent product).
(5) Position luggage rack on roof with screw holes
REMOVAL aligned.
(1) Remove slide rail screws. (6) Install and tighten slide rail screws with 3 N»m
(2) Remove luggage rack from roof. (28 in-lbs) torque.
J BODY COMPQNENTS-XJ VEHICLES 23 - 37
DOORS
INDEX
page page
Door Alignment Adjustment—Major 50 Front Door Window Glass Regulator 51
Door Alignment Adjustment—Minor . . . . . . . . . . . 49 Liftgate Adjustment 73
Door Edge Guard/Edge Protector Strip 63 Liftgate Hinge 69
Door External Handle 59 Liftgate Latch/Key Lock Cylinder/Striker 70
Door Hinge Replacement 61 Liftgate License Plate Lamp Housing 74
Door Inside Latch Release and Lock Rods 60 Liftgate License Plate Screw Anchor and Bumper . 74
Door Key Lock Cylinder 57 Liftgate Opening Weatherstrip Seal 73
Door Latch . 59
Liftgate Removal/Installation . 68
Door Latch Adjustment . . . . . . . . . . . . . . . . . . . . 58
Door Removal/Installation 43 Liftgate Service Information—XJ Vehicles . . . . . . 67
Door Restraint Replacement 50 Liftgate Support Rod Ball Stud Replacement . . . . 72
Door Trim Panel 38 Liftgate Support Rod Cylinder . 72
Door Window Exterior Mouldings 63 Liftgate Support Rod Cylinder Disposal 72
Door Window Glass and Door Opening Liftgate Trim Panel 69
Weatherstrip Seals 65 Rear Door Fixed Window Glass 57
Front Door Spacer Blocks—Two-Door Vehicles . . 63 Rear Door Window Glass 56
Front Door Vent Window 53 Rear Door Window Glass Regulator 54
Front Door Window Glass 52 Service Information 37
SERVICE INFORMATION trim panels,

The door service procedures includes removal, in waterdams,
stallation and/or replacement of following door com door restraints,
ponents: front doors,
• door handles, rear doors (XJ vehicles only),
• armrests, window glass regulators,
Fig. 1 Front Door Trim Panel

23 - 38 10DY COMPONENTS-XJ VEHICLES J
REAR TRIM .RETAINER

DOOR PANEL
MOULDING
(IF E Q U I P P E D )
ARMREST
RETAINER' WASHER RIVET SCREW J9123-35
Fig. 2 Rear Door Trim Panel

• door vent and window glass, REMOVAL
• key lock cylinders, (1) Remove door inside latch release handle screws
• door half-hinges, (Figs. 3 and 4).
• liftgate (XJ vehicles only),
DOOR
• liftgate hinges (XJ vehicles only), BEZEL
HANDLE
• liftgate gas support rod cylinders (XJ vehicles only),
• rocker panel seals, and
• mouldings/weatherstrip seals.
DOOR TRIM PANEL

SERVICE INFORMATION
All attached components can be removed from door
trim panels (Figs. 1 and 2).
CRANK
TRIM HANDLE
PANEL ARMREST
J8923-59
Fig. 4 Rear Door Inside Latch Release Handle

(2) Move door handle outward and disconnect han
dle-to-latch rods (Fig. 5). For vehicles equipped with
CONTROL power door locks/windows, disconnect wire harness
LINKAGE
connector (Fig. 6).
CONTROL (3) Remove regulator handle (Fig. 7) or, if
PANEL RETAINING equipped, power window switches and bezel.
SCREWS ,
m n
J898S-6
o e
(4) Remove armrest lower screws.
Fig. 3 Front Door Inside Latch Release Handle
J BODY C O I P O N E N T S - X J VEHICLES 23 - 39
TRIM PANEL- PANEL OPENING

LOCK-TO-LATCH ROD
(WITH RETAINER DOOR
CUP A N D BUSHING) TRIM
PANEL,
INSIDE
LATCH
RELEASE ROD GUIDE
AND LOCK BRACKET
HOUSING
HANDLE-TO-LATCH ROD
ROD RETAINER
HANDLE CLIP AND
BUSHING J9223-274 ESCUTCHEON
Fig. 5 Door Inside Latch Release Rods
DOOR TRIM •SCREW

PANEL
J9223-499
Fig. 8 XJ Front Door Armrest Removal/Installation

SCREW
DOOR DOOR
INNER PANEL TRIM
.PANEL
LONG
-BEZEL J9223-261
Fig. 6 Power Switch Wire Harness Connector

PLASTIC
.TRIM PANEL RETAINER
(ANCHOR) ARMREST
J9223-287
REGULATOR
SHAFT
Fig. 9 XJ Front Door Armrest Removal/Installation
SPACER
REGULATOR PLASTIC
HANDLE RETAINER
(ANCHOR)
XJ/MJ FRONT DOOR

-TRIM PANEL
REAR
REGULATOR
SHAFT DOOR
SPACER
REGULATOR
HANDLE N y
DOOR
INNER
PANEL
J9223-260 J9223-286
Fig. 7 Window Regulator Handles Fig. 10 XJ Rear Door Armrest Removal/Installation

(5) Pull armrest straight outward from panel and

remove bezel.
(6) For XJ vehicles, remove woodgrain moulding
from the door inner panel and the inner weatherstrip
seal (Figs. 11 and 12).
INNER INNER
WEATHERSTRIP WEATHERSTRIP SEAL
SEAL
MOLDING
TRIM WOODGRAIN J898S-8

PANEL MOLDING J9223-281
Fig. 13 Detaching Trim Panel Serrated Retainers

Fig. 11 XJ Woodgrain Moulding—Front Door
INNER WEATHERSTRIP FRONT REAR SERRATED TRIM
WEATHERSTRIP SEAL DOOR DOOR RETAINER PANEL
SEAL
BELT INNER
WEATHERSTRIP
SEAL
TRIM
DOOR PANEL
\ INNER
PANEL
MOLDING
TRIM WOODGRAIN REAR DOOR

MOLDING J9223-282 F R O N T DOOR TRIM PANEL
PANEL
TRIM PANEL J9223-299
Fig. 12 XJ Woodgrain Moulding—Rear Door

Fig. 14 Front & Rear Door Trim Panels
(7) Remove trim panel retainers from door inner
panel with a pry tool (Fig. 13).
(8) Remove trim panel from door (Fig. 14).
DOOR
STRING
INNER
CAULK
PANEL R E | ORCEMENT
N F
PANEL
PLASTIC-
COVERED CLOTH-BACK
SIDE TAPE
ADHESIVE
AREA
WATERDAM
DOOR
DOOR LATCH INNER WATERDAM
INNER RELEASE PANEL
PANEL A N D LOCK
WATERDAM RODS J9223-279
Fig. 17 Latch Release & Lock Rod Waterdam

FOR
WINDOW SPEAKER O P E N I N G
REGULATOR COVER WATERDAM ^FOLD DOOR FOLD
HANDLE .INNER
PANEL DOOR
INNER
J9123-145
PANEL
Fig. 15 Front Door Waterdam
SWITCH
DOOR STRING DOOR HOUSING
OUTER CAULK INNER
PANEL ADHESIVE
PANEL
I CLOTH-BACK WATERDAM
TAPE
DOOR
OUTER FRONT P O O R REAR DOOR
PANEL J9223-272
Fig. 18 Power Switch Waterdam

FRONT DOOR
TRIM PANEL
DOOR ADHESIVE SCREW

INNER AREA
PANEL
ASH WATERDAM SCREW

RECEIVER
POCKET J9123-146
Fig. 16 Rear Door Waterdam STOWAGE

BIN PANEL
(9) If necessary, remove waterdams from door.
(10) If necessary, remove storage bin panel and PUSH-NUT
SPEAKER
speaker grille from front door trim panel (Fig. 19). GRILLE
J9223-267
Fig. 19 Storage Bin Panel & Speaker Grille

23 - 4 2 1 0 D Y C O i P O N E N T S - X J VEHICLES J
(11) If necessary, remove ash receiver tray housing INSTALLATION

from rear door trim panel (Fig. 20). (1) If door waterdams were removed,apply sealant
to edges before installing them (Fig, 23).
DOOR
INNER
PANEL
OUTER FRONT DOOR REAR DOOR
rANtL. J9223-272
(WITHOUT SPEAKER) J9223-266
Fig. 20 Ash Receiver Tray Housing
(12) If necessary, replace armrest upper retainer Fig. 23 Waterdam installation
clip, retainer clip anchor and armrest support (2) Position waterdam on door inner panel (Fig. 23).
bracket. (3) If removed, install storage bin panel and
speaker grille on front door trim panel.
DOOR RETAINER
DOOR INNER CLIP (4) If removed, install ash receiver tray housing on
rear door trim panel.
(5) Position trim panel on door inner panel and
press retainers inward.
(6) Install armrest and window glass regulator han
dle. Or (if equipped) power window switches and bezel.
Tighten armrest screws with 4 N»m (34 in-lbs) torque.
(7) Connect rods to inside latch release handle and
install handle. Tighten screws with 2 N«m (16 in-lbs)
torque. For vehicles with power door locks/windows
connect wire harness connector.
CUP UPPER
RETAINER
CLIP J9223-285
Fig. 21 Armrest Upper Retainer Clip & Anchor
Fig. 22 Armrest Support Bracket

BODY COiPONENTS-XJ VEHICLES 23 - 43
DOOR REMOVAL/INSTALLATION DOOR

POWER SWITCH SECURITY ALARM DOOR
REMOVAL
W ! R E
MWROR S W I T C H C O N N E O O R LOCK
(1) Remove door restraint (check) retaining pin CONNECTOR H A R N E S S , CDHKIT \ CYLINDER/
(Fig. 24) with a punch. GROMMET
COWL
SIDE j
'PANEL
SECURITY
ALARM
RETAINER SWITCH
RESTRAINT CLIP
BRACKET POWER POWER
WINDOW D O O R LOCK
REGULATOR MOTOR
MOTOR CONNECTOR
SECURITY ALARM CONNECTOR
SWITCH WIRE \
| H A R N E S S CONNECTOR \
SPEAKER
DOOR W I R E
CONNECTOR
H A R N E S S CONNECTOR J9223-293
Fig. 26 XJ Right Front Door Wire Harness

Connectors—With Security Alarm Switch
DOOR
RESTRAINT LEFT POWER POWER
FRONT SWITCH ^ M I R R O R CONNECTOR
D O O R \ CONNECTOR
DASH
PANEL
Fig. 24 Door Restraint Retaining Pin
TO
(2) For vehicles equipped with power windows and I/P
CONDUIT
power door locks, remove trim panel and disconnect
RETAINER
all components. Slide wire harness out of boot and CLIP
door. OOR
WIRE
POWER P O W E R SWITCH FOAM
HARNESS
MIRROR CONNECTOR TAPE
P O W E R DOOR COWL
CONNECTOR
LOCK M O T O R SIDE
POWER PANEL
DASH CONNECTOR
WINDOW SPEAKER
PANEL
R E G U L A T O R CONNECTOR B O D Y W I R E H A R N E S S
M O T O R CONNECTOR J9223-292
DOOtf
WIRE
HARNESS. Fig. 27 XJ Left Front Door Wire Harness Connectors
COWL
SIDE P A N E L
BODY
WIRE
HARNESS <JWDJ P O W E R DOOR LOCK
- M O T O R CONNECTOR
POWER WINDOW "
SPEAKER REGULATOR
CONNECTOR M O T O R CONNECTOR J9223-291
Fig. 25 XJ Right Front Door Wire Harness

Connectors
(3) Remove door hinge bolts, plates and shims (Fig.
30). Remove door from vehicle.
(4) Identify and retain the door hinge plates and
the shims for correct installation (Fig. 30).
Fig. 28 XJ Rear Door Wire Harness Connectors
HINGE
HINGE
BOLTS
PLATE
J8923-58
Fig. 30 Door Hinges, Bolts, Plates & Shims

1 0 D Y C O M P O N E N T S - X J VEHICLES 23 - 4 i
J
INSTALLATION (2) Before installing a replacement door, transfer
(1) If a new front door is being installed, coat the original window glass, and components to replace
door interior with anti-corrosion wax. Seal the door ment door.
flange with sealant (Fig. 31). (3) Position the door in the body opening.
(4) Align door hinges, plates and shims with bolt
holes and install hinge bolts.
(5) Position door restraint (check) in bracket with
holes aligned and insert pin. Tap pin to seat it in the
bracket.
(6) Align/adjust door as necessary. Tighten hinge
bolts with 35 N«m (26 ft-lbs) torque.
(7) Apply general purpose sealant around door
hinges/door face mating area (Fig. 31).
(8) Adjust/align latch striker and latch as neces
sary.
(9) If applicable, route and connect the wire har
ness connectors.
(10) Install door water dam (if removed), trim
panel, armrest and regulator handle.
Fig. 31 Replacement Door Preparation
Fig. 32 Front Door Without Power Windows

Fig. 33 Front Door With Power Windows

J BODY C 0 1 P O N E N T S - X J VEHICLES 23 - 4 7
PLUG
J8923-56
Fig. 34 Rear Door Without Power Windows

J
J BODY COMPONENTS—XJ VEHICLES 23 • 49
DOOR ALIGNMENT ADJUSTMENT-MINOR

Minor adjustment for alignment of the door is
made by moving the latch striker. Refer to Door
Alignment (Minor) chart.
XJ DOOR ALIGNMENT-MINOR
D O O R / B O D Y A L I G N M E N T CONDITION ALIGNMENT CORRECTION
n D O O R CHARACTER LINE 1 Open the door and loosen the striker.

\ \ IS H I G H E R T H A N B O D Y 2 Tap the striker downward a sufficient distance to correct
\ \ CHARACTER LINE mismatch.
3 Tighten the striker and close the door.
4 Observe the door/body alignment.
I 5 If alignment is O K , open the door and tighten striker* with
71 N-m ( 5 2 ft. lbs.) torque.
- T O L E R A N C E : 1.5 mm ( 0 . 0 6 in.) 6 If alignment is not O K , adjust striker as described above.
D O O R CHARACTER LINE V\
1 Open the door and loosen the striker.
IS L O W E R T H A N B O D Y 111
CHARACTER LINE 2 Tap the striker upward a sufficient distance to correct
mismatch.
1 / 3
4
Tighten the striker and close the door.
Observe the door/body alignment.
5 If alignment is O K , open the door and tighten the striker* with
7 1 N-m ( 5 2 ft. lbs.) torque.
T O L E R A N C E : 1.5 mm (0.06 in.) 6 If alignment is not O K , adjust striker as described above.

D O O R CHARACTER LINE \ \ \ \
IS O U T B O A R D O F B O D Y \\ 1 I 1 2 Tap the striker inward a sufficient distance to correct
mismatch.
4 Observe the door/body alignment.
CHARACTER " ^ ^ ^ ^ ^ ^ ^
6 If alignment is not O K , adjust striker as described above.
T O L E R A N C E : 1.5 ^mm ( 0 . 0 6 in.)

D O O R C H A^R A C T E R ^L I"N"E ^
\ \ IS I N B O A R D O F B O D Y
1 1 CHARACTER LINE 2 Tap the striker outward a sufficient distance to correct
mismatch.
I 4 Observe the door/body alignment.

T O L E R A N C E : 1.5 mm (0.06 in.) 6 If alignment is not O K , adjust striker as described above.
*The center line ( f ) of the striker anti-snag fab must be horizontal ( ± 6 m m / 1 / 4 in.).
J9223-288
23 - 50 BODY COMPONENTS—XJ VEHICLES
DOOR ALIGNMENT ADJUSTMENT—MAJOR

Adjustment for alignment of the door is made by in
stalling shims between hinge plates and door face (Fig.
36).
(•jit RESTRAINT
BRACKET
HINGE
PLATES
ADJUSTMENT
SHIMS
DOOR
RESTRAINT
IJ9223-505
1 Fig. 37 Door Restraint (Check) Retaining Pin
A-PILLAR
RETAINING
PIN
J8923-32
Fig. 36 Door Adjustment Shims DOOR
(1) If not loosened, loosen the door hinge bolts (Fig. RESTRAINT
30).
(2) Add or remove shims as necessary to obtain the
best door fit.
(3) Tighten door hinge bolts with 35 N-m (26 ft-
lbs) torque after adjustment is completed.
(4) Apply general purpose sealant around door
hinges/door face mating area. RESTRAINT /
BRACKET
DOOR
DOOR RESTRAINT REPLACEMENT INNER SPEAKER
REMOVAL
PANEL OPENING
J9223-283
(1) Remove door trim panel. Fig. 38 Door Restraint (Check)—Front Door
(2) Front door: remove door radio speaker from RETAINING
door inner panel. PIN
(3) Remove door restraint (check) retaining pin
from bracket with a punch (Fig. 37). B-PILLAR DOOR
RESTRAINT
(4) Remove nuts and remove restraint via speaker RESTRAINT
opening (front door) or access opening (rear door) in BRACKET
door inner panel.
NUT
INSTALLATION
(1) Position door restraint in the door by way of
the opening and install nuts. Tighten the nuts with
10 N T H (7 ft-lbs) torque.
(2) Position door restraint in bracket with holes
DOOR
aligned and insert retaining pin (Fig. 37). INNER ACCESS
(3) Front door: install radio speaker and door trim f PANEL OPENING J9223-284
panel.
(4) Rear door: install door trim panel. Fig. 39 Door Restraint (Check)—Rear Door
J BODY COWIPONENTS-XJ VEHICLES 23 - 51
FRONT DOOR WINDOW GLASS REGULATOR

REMOVAL
(1) Remove door trim panel and waterdam.
(2) Remove window glass front channel bottom
screw (Fig. 40).
J8923-33
Fig. 40 Window Glass Front Channel Bottom Screw

(3) Remove window regulator rivets by driving the
rivet centers out with a punch. Remove rivets with a
1/4-inch drill bit (Figs. 41 and 42).
WINDOW
GLASS J9223-501
Fig. 43 Regulator-To-Glass Screw

(6) Lift window glass upward and separate it from
regulator. Support window glass.
(7) Remove window glass regulator from door.
INSTALLATION
(1) Position window glass regulator within door
panels.
(2) Attach regulator on door inner panel with re
placement rivets or screws and nuts.
(3) Remove support and position window glass at
regulator. Install regulator-to-window retainer, bush
Fig. 41 Manual Window Regulator Rivets ing and screw.
(4) Tighten regulator-to-glass screw with 4 N»m
(4) Lower window to provide access to regulator-to- (36 in-lbs) torque.
glass screw. (5) Install glass channel bottom screw (Fig. 40).
(5) Remove regulator-to-glass screw, bushing and Tighten screw with 9 N*m (7 ft-lbs) torque.
retainer from regulator (Fig. 43).
23 - 12 10DY C01PONENTS-XJ VEHICLES J
DOOR WIRE DOOR

INNER HARNESS INNER
RIVET
PANEL RETAINER CUP PANEL
FRONT POWER
MANUAL DOOR WINDOW
REGULATOR
WINDOW
MOTOR
REGULATOR
BRACKET
RIVET
DOOR
INNER
PANEL
OPENING SUPPORT
BRACKET
MOTOR
RETAINER W I N D O W REGULATOR
BRACKET
BRACKET J9223-303 WIRE HARNESS
RIVET
Fig. 44 Manual Regulator Installation—Upper Rivets Fig. 47 Power Regulator Installation—Lower Rivets
FRONT WINDOW FRONT DOOR WINDOW GLASS
DOOR GLASS
REMOVAL
SCREW A N D (2) Remove window glass channel hardware, belt-
BUSHING
line moulding and weatherstrip seals (Figs. 48 and
49).
W I N D O W
GLASS WEATHERSTRIP
RIVET VENT
GLASS BELT
MOULDING
FRONT
DOOR
ATTACHING WINDOW
ARM J9223-300
REGULATOR
FRONT
Fig. 45 Manual Regulator Installation—Lower Rivets
CLIP WEATHERSTRIP
& Glass Retaining Screw
I A W I N D O W
WEATHER 'GLASS
STRIP
POWER BELT
WINDOW
MOULDING
REGULATOR FRONT FLANGE
REAR
DOOR FLANGE "FRONT
CLIP
CLIP
(3 F O R 4 - D O O R ,
DOOR 4 FOR 2-DOOR)
INNER J91 2 3 - 1 0 5
PANEL
Fig. 48 Front Door Beltline Moulding & Weatherstrip
RIVET
Seals
(3) Remove glass channel bottom screw.
OPENING^
J9223-302
(4) Remove regulator-to-window glass screw, bush
RETAINER B R A C K E T
ing and retainer (Fig. 43).
Fig. 46 Power Regulator Installation—Upper Rivets (5) Lift glass upward and out of door.
(6) Attach door waterdam to door inner panel with INSTALLATION
sealant. (1) Position glass in door and install regulator-to-
(7) Install trim panel. glass retainer, bushing and screw.
(2) Tighten screw with 4 N*m (36 in-lbs) torque.
J BODY C O I P O N E N T S - X J VEHICLES 2 3 - 13
OUTER (5) Attach the door waterdam to the door inner

BELT W E A T H E R S T R I P panel with adhesive/sealant.
SEAL
(6) Install door trim panel.
DOOR
OUTER FRONT DOOR VENT WINDOW
PANEL
REMOVAL
(2) Remove window glass channel bottom screw.
(3) Remove vent window glass frame screws (Fig.
52).
DOOR
INNER GLASS
J9123-142 VENT
PANEL CHANNEL
FRAME
SCREWS
Fig. 49 Front Door Weatherstrip Seals
(3) Install channel bottom screw. Tighten screw
with 9 Nin (7 ft-lbs) torque.
(4) Install channel hardware, beltline moulding
and weatherstrip seals.
WINDOW
GLASS
DOOR
INNER
PANEL
J8923-34
Fig. 52 Vent Window Glass Frame Screws

BELT
OUTER (4) Tilt vent window glass frame and front channel
WEATHERSTRIP
SEAL
rearward, and remove both as a unit (Fig. 52).
RETAINER
(5) Remove vent window glass latch pin and latch
CLIP J9223-257 (Fig. 53).
(6) Remove glass hinge screw.
Fig. 50 Front Door Belt Outer Weatherstrip Seal (7) Remove pivot nut and the spring.
FRONT DOOR (8) Remove vent window glass from frame.
BELT
INNER
WEATHERSTRIP
SEAL
DOOR INNER
PANEL FLANGE J9223-256
Fig. 51 Front Door Belt Outer Weatherstrip Seal

LATCH
HANDLE
PIVOT
SPRING
AND N U T
J8923-38
Fig. 53 Vent Window Glass Disassembly/Assembly

INSTALLATION SCREW DOOR W I N D O W
(1) Position vent window glass in frame and install FRAME
hinge screw, spring and pivot nut (Fig. 53).
DOOR V E N T
(2) Install window glass latch and pin. WINDOW FRAME
(3) Install vent window glass and the channel in
the door (Fig. 54). FRONT
(4) Install vent window glass frame screws (Fig. DOOR
DOOR
WINDOW
54). GLASS FRONT
(5) Install door window glass channel bottom CHANNEL
screw.
(6) Install door waterdam and trim panel. SCREW
REAR DOOR WINDOW GLASS REGULATOR DOOR

WINDOW INNER WINDOW
REMOVAL GLASS PANEL REGULATOR J9223-298
(2) Remove window glass attaching screw, bushing Fig. 54 Vent Window Frame & Front Channel
and retainer from regulator (Fig. 55). Support glass. Installation
(3) Remove regulator rivets by driving out rivet (4) Power window: disconnect wire harness connec
center with a punch. Next, drill out the rivet body tor from regulator drive motor.
with a 1/4 inch diameter drill bit (Fig. 56). (5) Remove regulator and drive motor, if equipped.
j ^ _ • BODY COMPONENTS-XJ VEHICLES 23 - 55
ANCHOR RETAINER AAANUAL REAR

(WITH TABS) WINDOW DOOR
REGULATOR
DOOR
INNER
PANEL
BRACKET OPENING
RIVET
RETAINER
REGULATOR
SCREW A N D BRACKET
BUSHING
WINDOW
J9223-501 J9223-305
GLASS
Fig. 55 Regulator-To-Glass Screw Fig. 57 Manual Regulator Rivet Installation

POWER REAR
WINDOW DOOR
REGULATOR
DOOR
INNER
PANEL
OPENING
RIVET
J9223-304
RETAINER BRACKET
Fig. 58 Power Regulator Rivet Installation

REGULATOR MOTOR REGULATOR LOWER WIRE HARNESS
W I R E HARNESS BRACKET / RETAINER CUP
J8923-62
Fig. 56 Rear Door Window Regulator Rivets

INSTALLATION WINDOW
(1) Position window regulator and, if equipped, GLASS
drive motor within door panels.
(2) Attach regulator to door inner panel with re DOOR INNER
placement rivets or with screws and nuts. PANEL
(3) Connect regulator wire harness connector.
(4) Position window glass at regulator and install
retainer, bushing and screw.
(5) Tighten glass screw with 4 N*m (36 in-lbs) RIVET J9223-273
torque.
(6) Install waterdam and trim panel. Fig. 59 Power Regulator Lower Bracket Rivet
Installation
REAR DOOR WINDOW GLASS

REMOVAL
(1) Lower window glass.
(2) Pry window beltline moulding from clips and
remove moulding from door.
(3) Remove window weatherstrip seals from door
(Fig. 60).
OUTER
Fig. 62 Window Channel/Division Bar Rivet

(7) Remove window glass screw, bushing and re
tainer from regulator (Fig. 63).
Fig. 60 Rear Door Window Weatherstrip Seals

(4) Remove trim panel and waterdam from door in
ner panel. WINDOW
(5) Remove channel/division bar screws and drill- GLASS J9223-501
out rivet head to remove.
Fig. 63 Regulator-To-Glass Screw
(8) Remove window glass from door.
INSTALLATION
(1) Install glass in door, and install retainer, bush
ing and screw (Fig. 63).
(2) Tighten glass attaching screw with 6 N*m (53
in-lbs) torque.
(3) Install window glass channel/division bar in
door.
(4) Install window glass channel/division bar
screws and rivet. Tighten screws with 6 N»m (5 ft-
lbs) torque.
(5) Install window glass channel and belt weather
Fig. 61 Window Channel/Division Bar Screws & strip seals.
Rivet (6) Install window beltline moulding.
(7) Install door waterdam and trim panel.
(6) Tilt channel/division bar forward and remove it
from door.
J BODY C O i P O N E N T S - X J VEHICLES 23 - 57
REAR DOOR FIXED WEATHERSTRIP REAR

W I N D O W FRAME GLASS SEAL DOOR
DIVISION
BAR DOOR
INNER
PANEL
GLASS CHANNEL RIVET
WEATHERSTRIP
SEAL
START
LOCATION
BOLT
DOOR GLASS
J9223-259 OUTER SUPPORT
PANEL BRACKET J9223-290
Fig. 64 Glass Channel Weatherstrip Seal
Fig. 66 Fixed Glass Support Bracket Bolts
BELT REAR BELT REAR
BELT OUTER
FRONT DCOR OUTER WEATHERSTRIP v^^jHERSTRIP FIXED REINFORCEMENT
OUTER 5 E A L
SEAL WINDOW BRACKET
WEATHERSTRIP GIASS
FIXED
SEAL WINDOW
GIASS'
DOOR
DOOR OUTER
OUTER BOLT
PANEL
PANEL
GLASS
SUPPORT
AND DOOR
DEFLECTOR INNER
PANEL
WELD
NUT
GIASS
SUPPORT DEFLECTOR J9223-262
Fig. 67 Fixed Glass Removal/installation

INSTALLATION
DOOR INNER (1) Install fixed glass in door, and install bolts in
PANEL
FLANGE J9223-258 reinforcement and support brackets.
(2) Tighten bracket retaining bolts with 9 N*m (79
Fig. 65 Belt Weatherstrip Seals in-lbs) torque.
REAR DOOR FIXED WINDOW GLASS (3) Install channel/division bar in the door.
(4) Install channel/division bar screws and rivet.
REMOVAL Tighten screws with 6 N*m (5 ft-lbs) torque.
(1) Lower window glass. (5) Install channel and belt weatherstrip seals.
(2) Pry window beltline moulding from clips and (6) Install beltline moulding.
remove moulding from door. (7) Install door waterdam and trim panel.
(3) Remove window weatherstrip seals from door.
(4) Remove trim panel and waterdam from door in DOOR KEY LOCK CYLINDER
ner panel.
REMOVAL
(5) Remove channel/division bar screws. Drill out
rivet head to remove it from inner panel.
(2) Disconnect door latch-to-lock cylinder rod at
(6) Tilt channel/division bar forward and remove it
door latch (Fig. 68).
from door.
(3) If equipped, disconnect the security alarm
(7) Remove fixed glass support bracket bolts from
switch connector from lock cylinder (Fig. 69).
door inner panel reinforcement bracket (Fig. 66).
(4) Remove key lock cylinder retainer clip. Remove
(8) Remove fixed glass from door (Fig. 67).
the lock cylinder, gasket and clip from door opening
(Fig. 70).
J
RETAINER
CLIP
DOOR
LATCH HANDLE
LATCH RELEASE-
TO-LATCH ROD
LOCK CYLINDER-TO-LATCH R O D
LOCK CYLINDER-
TO-LATCH ROD
ROD CLIP
ADJUSTMENT AND
SCREW BUSHING J9223-513
J9223-506
Fig. 68 Key Lock Cylinder & Door Latch

Fig. 70 Key Lock Cylinder Removal/Installation
SECURITY
ALARM
(4) Test and, if necessary, adjust door latch-to-lock
SWITCH cylinder rod operation.
I FRONT
(5) Install door trim panel and waterdam.
JU^DOOR
LOCK DOOR LATCH ADJUSTMENT

CYLINDER (1) Remove access hole plug from latch face (Fig.
SECURITY
ALARM 71).
SWITCH
SERRATED
RETAINER
LATCH
RELEASE
HANDLE
LATCH LATCH
RELEASE-TO-LATCH
WIRE HARNESS ROD
CONNECTOR J9223-278
Fig. 69 Security Alarm Switch

(5) If applicable, remove door latch-to-lock cylinder
rod from original lock cylinder. Connect it to replace LOCK
CYLINDER-TO-
ment lock cylinder. ACCESS LATCH R O D
HOLE
ADJUSTMENT
INSTALLATION SCREW
(1) Position lock cylinder and gasket in door open HEX
f WRENCH J9223-500
ing. Hold lock cylinder in opening with retainer clip.
(2) Connect door latch-to-lock cylinder rod to door Fig. 71 Door Latch Adjustment
latch.
(2) Insert a 5/32-inch wrench through hole and
(3) If equipped, connect security alarm switch con
into latch release lever adjustment screw and loosen.
nector to lock cylinder.
J BODY C 0 M P 0 N E N T S - X J VEHICLES 23 - 59
(3) Press and release outside door handle latch re

lease button several times.
(4) Release button and tighten adjustment screw
with 3 N»m (30 in-lbs) torque.
(5) Test release handle button and key lock cylin
der for proper latch release.
(6) Install door waterdam and trim panel.
DOOR EXTERNAL HANDLE
REMOVAL
(2) Remove access hole cover and remove door han
dle nuts (Fig. 72).
COLLET
J8923-42
Fig. 73 Door Handle Components
Fig. 72 Door External Handle Removal/installation

(3) Disconnect handle-to-latch rod from handle
latch release lever arm.
(4) Remove nuts and handle from door.
(5) Remove gaskets from door outer panel surface,
if necessary. J8923-45
INSTALLATION Fig. 74 Access Plug

(1) Assemble the replacement door handle, if nec (4) Remove door latch screws (Fig. 75).
essary (Fig. 73). Apply silicone spray lubricant to
(5) Remove retainer clip and key lock cylinder
components.
from door outer panel.
(2) If original gaskets were removed, position re
(6) Disconnect all rods from door latch (Fig. 76).
placement gaskets on handle. Position handle on
door outer panel. (7) Remove door latch from door face.
(3) Install and tighten handle nuts. (8) For vehicles equipped with power door locks,
(4) Connect latch-to-handle rod to handle latch re remove lock motor rivets. Remove motor and latch as
lease lever arm. a unit from door. Detach rod and motor from latch
(5) Install door waterdam and trim panel. (Fig. 77).
DOOR LATCH INSTALLATION

(1) If necessary, install a replacement latch
REMOVAL striker.
(1) Remove access plug located at upper end of (2) For vehicles equipped with power door locks,
door (Fig. 74). attach rod and lock motor to latch. Attach lock motor
(2) Remove door trim panel and waterdam. to door panel with either rivets or with bolts and
(3) Remove door external handle from door outer nuts (Fig. 77).
panel.
DOOR LATCH
RETAINER CLIP
A N D BUSHING
DOOR
LOCK
MOTOR
RIVET
DOOR DOOR
INNER LOCK
J9223-301
PANEL MOTOR
DOOR
LATCH
SCREWS Fig. 77 Door Lock Motor
DOOR SHIM LATCH DOOR LATCH
PILLAR WASHER STRIKER PILLAR STRIKER
J8923-43 I ANTI-SNAG
TAB
ANTI-SNAG
TAB
TAB
Fig. 75 Door Latch Retaining Screws SHIELD
LOCK O U T S I D E LATCH REAR O U T S I D E LATCH
SHIM
CYLINDER-TO- RELEASE H A N D L E - DOOR RELEASE HANDLE-
WASHER
LATCH R O D ^ * TO-LATCH R O D LATCH T O - L A T C H ROD
FRONT RETAINER CLIP
' D O O R RETAINER BUSHING
LATCH C U P A N D
BUSHING INSIDE
<fc O F T A B
INSIDE LOCK-
M U S T BE
LOCK-TO-LATCH TO-LATCH
HORIZONTAL
ROD / ROD
( ± 6 m m / / 4 IN)
,
J9223-347
NSIDE R E L E A S E
INSIDE
HANDLE-TO-LATCH
RELEASE Fig. 78 Door Latch Striker Removal/Installation
ROD
POWER HANDLE-TO-
ADJUSTMENT
ADJUSTMENT DOOR LOCK LATCH R O D
SCREW
SCREW MOTOR-TO- RIGHT REAR
POWER
RIGHT FRONT LATCH R O D D O O R LATCH
DOOR LOCK
D O O R LATCH J9223-296
M O T O R - T O - LATCH R O D
Fig. 76 Door Latches

(3) Install door latch at door face and connect all
rods to latch (Fig. 76).
(4) Install the latch screws. Tighten the screws
with 9 N«m (77 in-lbs) torque.
(5) Install door external handle.
(6) Install latch-to-door handle rod.
(7) Install key lock cylinder and retainer clip.
(8) Install door waterdam and trim panel. CONTROL
LINKAGE
(9) Install door access plug.
CONTROL
DOOR (NSIDE LATCH RELEASE AND LOCK RODS PANEL RETAINING
SCREWS
J898S-6
REMOVAL
(1) Remove door inside latch release handle screws Fig. 79 Front Door Inside Latch Release Handle
(Figs. 79 and 80).
equipped with power door locks/windows, also discon
(2) Move door release handle outward and discon
nect handle-to-latch rods (Fig. 81). For vehicles nect wire harness connector (Fig. 82).
J i O D Y COMPONENTS-XJ VEHICLES 23 - 61
DOOR
BEZEL
HANDLE DOOR TRIM
PANEL
WIRE
HARNESS
CONNECTOR
SCREW
-BEZEL J9223-261
Fig. 82 Power Switch Wire Harness Connector

CRANK FRONT
TRIM HANDLE
ARMREST DOOR
PANEL
J8923-59 0 ANTI-RATTLE
DOOR SLEEVE
OUTER
Fig. 80 Rear Door Inside Latch Release Handle PANEL
TRIM PANEL- PANEL OPENING

LOCK-TO-LATCH ROD
(WITH RETAINER
CUP A N D BUSHING)
INSIDE OPENING
LATCH
RELEASE ROD STAND-OFF
ROD GUIDE LOCK-TO-
A N D LOCK GUIDE SILENCER
BRACKET LATCH
HOUSING BRACKET ROD
HANDLE-TO-
LATCH ROD
DOOR
INNER PANEL J9223-275
Fig. 83 Front Door Rod Guide Bracket & Rods

HANDLE-TO-LATCH ROD
ROD GUIDE
BRACKET
ROD RETAINER
HANDLE CLIP AND
BUSHING J9223-274 LOCK-TO-
LATCH ROD
Fig. 81 Door Inside Latch Release Rods ANTI-RATTLE
SLEEVE
(4) Drill-out rivet heads and remove rod guide
bracket rivets from door inner panel (Figs. 83 and
84).
(5) Remove rod guide brackets and rods from door. LOCK-TO-
LATCH ROD
INSTALLATION HANDLE- DOOR HANDLE-TO-
(1) Position rod guide brackets and rods in door. TO-LATCH INNER LATCH ROD
ROD PANEL J9223-277
(2) Install rod guide bracket rivets in door inner
panel (Fig. 85). Fig. 84 Rear Door Rod Guide Bracket & Rods
(3) Install door trim panel and waterdam.
(2) Front door: open door wide for access and re
DOOR HINGE REPLACEMENT move door hinge pin and bushing with a punch.
(3) Rear door: with door closed, remove door hinge
REMOVAL pin and bushing with a punch (Fig. 87).
(1) Remove door restraint (check) retaining pin (4) Remove door hinge bolts, plates and shims (Fig.
(Fig. 86) with a punch. 88).
ROD B-PILLAR
GUIDE
BRACKET
HINGE
COVER
ROD
GUIDE
DOOR BRACKET
LATCH
DOOR RIVET REAR

INNER RIVET REAR DOOR
J9223-276 HINGE J9223-265
PANEL DOOR
Fig. 85 Rod Guide Bracket Installation Fig. 87 Rear Door Hinge

HINGE
SHIM PLATES SHIM
RESTRAINT
BRACKET
HINGE
SHIM
DOOR
HINGE
RESTRAINT
BOLTS
Fig. 86 Door Restraint (Check) Retaining Pin

(5) Retain door hinge plates and shims for correct
installation.
(6) Separate hinge halves.
INSTALLATION
(1) Position hinge plates, shims and replacement
hinge-half on door face. PLATE
(2) Align door hinges, plates and shims with bolt J8923-58
holes and install hinge bolts.
(3) Join hinge halves and align bushing/retaining Fig. 88 Door Hinges, Bolts, Plates & Shims
pin holes. (6) Position the door restraint in bracket with
(4) Front door: open door wide for access. Install holes aligned and insert pin. Tap pin to seat it in
replacement hinge bushing and replacement pin with
bracket.
a punch and hammer.
(7) Align/adjust door as necessary. Tighten hinge
(5) Rear door: with the door closed, install the re
bolts with 35 N*m (26 ft-lbs) torque.
placement hinge bushing and the replacement pin
with a punch and hammer.
(8) Apply general purpose sealant around door (3) Lower spacer block: install screws in door face.
hinge/door face mating area. Tighten screws with 1 N»m (11 in-lbs) torque.
(9) Adjust/align latch striker and latch as neces
sary. DOOR EDGE GUARD/EDGE PROTECTOR STRIP
FRONT DOOR SPACER BLOCKS—TWO-DOOR REPLACEMENT

(1) Pull outward and remove door edge guard strip
VEHICLES
from door edge (Fig. 91).
REMOVAL DOOR INNER
(1) Upper spacer block: drill-out rivet heads and PANEL DOOR EDGE
remove from reinforcement plate. GUARD OR
PROTECTOR
F R O N T DOOR WINDOW STRIP
W I N D O W FRAME RIVET OUTER
FRAME
WINDOW \
INNER-*i DOOR EDGE DOOR OUTER
FRAME PROTECTOR PANEL
RIVET STRIP
REINFORCEMENT
FRONT DOOR
PLATE D O O R
UPPER WOODGRAIN
WINDOW OUTER DOOR INNER
SPACER OVERLAY
FRAME PANEL
BLOCK (BRIARWOOD ONLY)
/ DOOR
REINFORCEMENT
PLATE
te
— UPPER I
SPACER
WINDOW RIVET BLOCK
INNER
ADHESIVE
FRAME J9223-297
DOOR EDGE DOOR OUTER
GUARD PANEL
Fig. 89 Front Door Upper Spacer Block—Two-Door DOOR EDGE EDGE
Vehicles FRONT OR REAR DOOR GUARD
J9223-264
(2) Lower spacer block: remove screws from door
Fig. 91 Door Edge Guard/Protector Strip
face (Fig. 90).
(2) Position door edge guard strip on door edge.
DOOR DOOR
SPACER FACE (3) Force door edge guard strip inward until it is
DOOR J seated on door edge.
/
FACE
DOOR WINDOW EXTERIOR MOULDINGS

DOOR REMOVAL
SPACER
(1) When removing front or rear door window ex
terior moulding, open window completely.
SCREW i
(2) Pry and pull moulding sections from door panel
flange and clips.
INSTALLATION
(1) When installing window mouldings, start at
J9223-263 forward end of upper moulding.
(2) Force moulding onto door panel and continue
Fig. 90 Front Door Lower Spacer Block— Two-Door rearward until it is completely seated on flange.
Vehicles (3) Mate rear moulding with upper moulding and
(3) As applicable, remove spacer block from door force moulding edge inward.
window frame or door face. (4) Continue pressing and moving downward to
complete installation.
INSTALLATION (5) Position lower moulding on clips and force it
(1) As applicable, position spacer block on door downward.
window frame or door face.
(2) Upper spacer block: Install replacement rivets
in spacer block and reinforcement plate (Fig. 89).
GLASS DOOR DOOR CHANNEL ^ FRONT WATER

CHANNEL INNER O UTER GLAS S DNT
O O %U
INNER
R
UPPER SOLUBLE
PANEL . 5T AL
FRONT P -
AN
-
E L
^LA55
MOULDNI G ^SHIM
UPPER P ANEL
MOULDN IG CHANNEL
GLASS WEATHERSTRIP DOOR
— SEAL O U TER PANEL
GLASS
DOOR FRONT REAR
OUTER UPPER MOULDN IG
PANEL FRONT M OULDN
I G
MOULDNIG REAR UPPERRG
LOWER I MOULDN IG I HT
MOULDN
IG LÔUTER MOULDN IG
i BELT
DOOR 1 WEATHERSTRIPGLASS
OUTER 81
SEAL INNER BELT
PANEL WEATHERSTRIP
SHIM SEAL
DOOR
OUTER DOOR
PANEL INNER
LOWER PANEL
MOULDNI G CLIP LOWER
FRONT MOULDN
IG
UPPER MOULDNIG J9123-143
Fig. 92 Front Door Window Exterior Moulding

DOOR GLASS DOOR UPPER WATER DOOR
OUTER CHANNEL INNER MOULDN
IG SOLUBLE OUTER
PANEL PANEL SHIM PANEL
CHANNEL REAR
WEATHERSTRIP MOULDNIG
UPPER SEAL
MOULDNIG
UPPER GLASS CHANNEL
MOULDN
IG WEATHERSTRIP
SEAL DOOR
INNER
GLASS PANEL
GLASS
CHANNEL
DOOR OUTER BELT DOOR
OUTER WEATHERSTRIP INNER REAR OUTER
PANEL SEAL BELT WEATHERSTRIP MOULDN I G PANEL
SEAL FRONT AND REAR
LOWER MOULDN
IG DOOR MOULDNIG
DOOR INNER
OUTER" PANEL
PANEL CLIP LOWER
MOULDN
IG J9123-141
Fig. 93 Rear Door Window Exterior Moulding

J BODY COMPONENTS—XJ VEHICLES 23 - i i
DOOR WINDOW GLASS AND DOOR OPENING FRONT SECONDARY

WEATHERSTRIP SEALS DOOR DOOR
SEAL SEAL
SECONDARY
REMOVAL DOOR
When removing front or rear door window glass SEAL
weatherstrip seals, open window.
The window weatherstrip seals can be removed by
hand or with the aid of a small putty knife (or sim
ilar tool).
OUTER
BELT W E A T H E R S T R I P
SEAL
DOOR
OUTER
PANEL
ENDS
MEET
AT
CENTERLINE
J9123-144
DOOR Fig. 96 Door Opening Weatherstrip Seals

GLASS
The door-to-rocker panel seals are attached to the
, N N E R
\ M ^ J9123-142
\ & > ^ PANEL CHANNEL
door inner panels with rivets (Fig. 97). The rivets
Fig. 94 Front Door Window Glass Weatherstrip can be removed with an appropriate pry tool.
Seals TRUSS
RIVET
OUTER
BELT W E A T H E R S T R I P DOOR
DOOR SEAL INNER
OUTER PANEL
PANEL
INNER
BELT SEAL
WEATERSTRIP
SEAL
F R O N T DOOR
DOOR
GLASS OUTER TRUSS
PANEL RIVET
CHANNEL
DOOR
INNER
PANEL
DOOR
GLASS
INNER
CHANNEL REAR DOOR J9123-140
PANEL SEAL
WEATHERSTRIP J9123-139
SEAL
Fig. 97 Door-To-Rocker Panel Seals
Fig. 95 Rear Door Window Glass Weatherstrip Seals WINDOW GLASS WEATHERSTRIP SEAL
The door opening weatherstrip seal is attached to INSTALLATION
the periphery of the door opening in the body. The When installing front or rear door window glass
retaining push-studs can be removed with an appro weatherstrip seals, open window completely.
priate pry tool. The front door secondary seal is at (1) To install a front door window glass channel
tached to the A-pillar with plastic blind rivets (Fig. weatherstrip seal, start at upper, rear corner (Fig.
96). 98).
23 - 66 IODY COMPONENTS—XJ VEHICLES
GLASS WN
I DOW
CHANNEL GIASS
WEATHERSTRIP
DOOR
INNER
PANEL
BELT
OUTER
WEATHERSTRP
I
SEAL
RETAN
I ER
CUP J9223-257
Fig. 100 Front Door Belt Outer Weatherstrip Seal

START IN CORNER
TO INSTALL
WEATHERSTRPI FRONT _DOOR
J8923-50
Fig. 98 Front Door Window Glass Channel
Weatherstrip Seal
(2) To install a rear door window glass channel
weatherstrip seal, start at upper, front corner (Fig.
99).
REAR DOOR
WN
I DOW FRAME BELT
INNER
WEATHERSTRP
I
SEAL
DOOR INNER
PANEL FLANGE J9223-256
GLASS CHANNEL
WEATHERSTRP
I Fig. 101 Front Door Belt Inner Weatherstrip Seal
SEAL
START BELT
LOCATOIN FRONT D ROORR OUTERBEW
EA LTEA
RTEH
AR
ERSTRP
I \Y^JHE^|||P
OUTER 5TAL
SEAL
WEATHERSTRP
I DOOR
SEAL WINDOW
GIASS MOLDN
IG
J9223-259 DOOR
OUTER
Fig. 99 Rear Door Window Glass Channel PANEL
Weatherstrip Seal
(3) A small amount of adhesive can be used to hold
weatherstrip seal in-place, if necessary.
(4) As applicable, move forward or rearward and
downward evenly until weatherstrip seal is fully
seated in channel.
(5) Position belt weatherstrip seals at window edge
(Figs. 100, 101 and 102) and force them downward
until seated on flange.
DOOR OPENING WEATHERSTRIP SEAL DOOR INNER

INSTALLATION PANEL
The weatherstrip seal is attached to flange around FLANGE J9223-258
the perimeter of the door opening with adhesive and Fig. 102 Rear Door Belt Outer & Inner Weatherstrip
plastic push-studs. Seal
(1) When installing a door opening weatherstrip ® - P R E S S INWARD

seal, start at door sill center line. FIRMLY AT
INDICATED AREA
(2) Use adhesive along with the push-studs to aid
in retaining a weatherstrip seal.
(3) Move upward and around the perimeter of the
door opening and seat weatherstrip seal on flange
(Fig. 103).
(4) Install front door secondary seal with plastic
blind rivets (Fig. 96).
DOort-TO-mocKm p a n e l s e a l
INSTALLATION
(1) Position seal on door inner panel with holes
aligned (Fig. 97).
(2) Attach seal to door inner panel with truss riv
ets. REAR DOOR
WEATHERSTRIP SEAL
FRONT DOOR FLANGE SEAL
LIFTGATE SERVICE INFORMATION-XJ VEHICLES WEATHERSTRIP SEAL FLANGE
The liftgate components are illustrated in Figure
104. J9223-271
Fig. 103 Door Opening Weatherstrip Seals
HINGE
HINGE PIN SHIM LIFTGATE
CYLINDER
MOUNTING
SHIM STUD
SEAL
ROOF
PANEL
SUPPORT
CYLINDER
WIPER
MOTOR LIFTGATE
STOP
LIFTGATE
REAR
LATCH
POWER SPEAKER
LOCK
SOLENOID
J9223-490
Fig. 104 Liftgate Components

LIFTGATE REMOVAL/INSTALLATION (3) Remove the retainer clips that secure the sup
port rod cylinders to ball studs (Fig. 106).
REMOVAL (4) Remove support rod cylinders from ball studs
(Fig. 106).
WARNING: D O N O T DISCONNECT S U P P O R T R O D (5) Remove screws and the wire harness trim cover
CYLINDERS WITH L I F T G A T E CLOSED. T H E S U P from liftgate header (Fig. 107).
P O R T R O D P I S T O N S A R E O P E R A T E D B Y HIGH
P R E S S U R E G A S . T H I S C O U L D C A U S E DAMAGE
AND/OR P E R S O N A L I N J U R Y I F T H E Y A R E R E
MOVED W H I L E P I S T O N S A R E C O M P R E S S E D .
(1) Open liftgate.

(2) Remove liftgate trim panel (Fig. 105).
HEADER
PANEL J9223-208
Fig. 107 Liftgate Wire Harness Trim Cover

(6) Disconnect connectors and remove wire harness
from liftgate (Fig. 108).
Fig. 108 Liftgate Wire Harness & Hinge Screws

(7) Remove hinge-to-liftgate screws (Fig. 108).
(8) Remove liftgate from vehicle.
INSTALLATION
(1) Position and support liftgate at opening in the
body and install the hinge-to-liftgate screws (Fig.
108).
(2) Adjust liftgate to fit properly in body opening.
Refer to Liftgate Adjustment.
J BODY C O M P O N E N T S - X J VEHICLES 23 - i i
(3) Tighten the hinge-to-liftgate screws with 9 N«m INSTALLATION

(7 ft-lbs) torque. (1) If removed, install trim panel retainer strip on
(4) Connect liftgate rod cylinders to ball studs and liftgate with replacement rivets.
install rod cylinder retainer clips (Fig. 106). (2) If removed, install speaker grilles on trim
(5) Insert and connect wire harness connectors panel. Tighten screws with 1 N*m (11 in-lbs) torque.
(Fig. 108). (3) Position trim panel on liftgate.
(6) Position wire harness trim cover on header and (4) Align trim panel retainers with Lo'es in lift
install screws (Fig. 107). Tighten screws with 1 N»m gate inner panel and force trim panel inward.
(11 in-lbs) torque. (5) Install screws to attach panel upper sides to
(7) Install trim panel (Fig. 105). liftgate.
LIFTGATE TRIM PANEL LIFTGATE HINGE
REMOVAL REMOVAL
(1) Remove screws that attach panel upper sides to It is not necessary to remove liftgate to replace one
liftgate (Fig. 105). or both hinges.
(2) Use a trim panel removal tool to detach the (1) Remove liftgate (headliner) upper trim mould
panel retainers from liftgate. ing (Fig. 111).
(3) Remove trim panel from liftgate.
(4) If necessary, drill-out rivet heads and remove
trim panel strip from the liftgate.
UFTGATE
LIFTGATE SCREW
STRIP UPPER TRIM
RETAINER MOULDING
HEADER
PANEL
LIFTGATE
UPPER TRIM
SCREW MOULDING
J9223-207
Fig. 111 Liftgate Upper Trim Moulding

(2) Remove the hinge-to-roof panel nuts (Fig. 112).
RIVET- J9223-151
JHINGE
Fig. 109 Liftgate Trim Panel Strip Retainer
(5) If necessary, remove screws and remove
speaker grilles from trim panel (Fig. 110).
SPEAKER
GRILLE SEAL
HINGE-TO-ROOF PANEL
NUTS
J8923-67
% ^ ^__TORX-HEAD
X SCREW
Fig. 112 Liftgate Hinge-To-Roof Panel Nuts
(3) Remove hinge-to-liftgate screws and remove
hinge from liftgate (Fig. 113).
J9223-153
Fig. 110 Liftgate Trim Panel Speaker Grilles

LIFTGATE LATCH/KEY LOCK CYLINDER/STRIKER

RIGHT
HINGE
REMOVAL
(1) Raise liftgate and remove latch screws (Fig.
115).
z LATCH
SCREWS
LATCH
4V
LIFTGATE
J9223-147
Fig. 113 Liftgate Hinges

INSTALLATION
(1) Position gaskets, shim and hinge on the liftgate
and the roof panel (Fig. 114).
HINGE
J8923-68
Fig. 115 Liftgate Latch Screws

SHIM
(2) Disconnect rod from latch (Fig. 116).
GASKET
AND
SEAL GASKET
J9223-148
Fig. 114 Liftgate Hinge, Gaskets & Shim

(2) Install and tighten hinge-to-roof panel nuts
with 9 N-m ( 7 ft-lbs) torque.
(3) Install liftgate-to-hinge screws. Tighten screws
with 9 N«m ( 7 ft-lbs) torque.
(4) Install liftgate (headliner) upper trim moulding
(Fig. 111).
J8923-69
Fig. 116 Latch & Key Lock Cylinder

— BODY COMPONENTS-XJ VEHICLES 23 - 71
(3) Remove latch from liftgate (Fig. 117). (6) Remove k

1993 Jeep Wrangler Service Manual

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SERVICE

To order the special service tools used and

NO PART OF THIS PUBLICATION MAY BE

Chrysler Corporation reserves the right to make changes in design or to make

Litho in U.S.A. Copyright © 1992 Chrysler Corporation 20M0992

GROUP TAB LOCATOR

SEE Instrument Panel & Gauges

SJ T u r n Signal/Hazard Warning Flasher

SBC Windshield Wipers & Washers

SP Power Door Locks

SU Chime/Buzzer Warning Systems

24 Heating And Air Conditioning

25 Emission Control Systems

Component and System Index

Service Manual Comment Forms (Rear of Manual)

DESIGNATIONS, LABELS/PLATES, CODES AND SPECIFICATIONS .... 8

DESIGNATIONS LABELS/PLATES, CODES AND DIMENSIONS

MFriRV CHRYSLER DATE OF MFR GVWR

GAWR FRONT WITH TIRES RIMS AT PSI COLD

GAWR REAR WITH TIRES RIMS AT PSI COLD

THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

VIN: TYPE: SINGLE DUAL

Fig. 2 XJ—Cherokee 2-Door Multi-Purpose Vehicle

VEHICLE CODE PLATE

Fig. 3 XJ—Cherokee 4-Door Multi-Purpose Vehicle

Country Vehicle Line Engine Sequential

Line #3 Digit 1 - 1 2 Vehicle Order Number

Lines 4 through 7 (if used) on the vehicle code

Cherokee 6-in Wheels XJ 257.6 144.8 144.8 420.0 179.1 161.0

Cherokee 6-in Wheels XJ 257.6 144.8 144.8 420.0 179.1 161.0

Wrangler YJ 237.2 147.3 147.3 387.6 167.7 176.5

VEHICLE INTERIOR DIMENSION DATA s

Cherokee XJ 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0

YJ RENEGADE N/A N/A 300 100 N/A N/A

All Weights Listed In Pounds. 2

VEHICLE CONTROL AND DISPLAY SYMBOLS

Multiply By To Get Multiply By To Get

Inches H g (60°F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches H g

Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches

mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

COMMON METRIC EQUIVALENTS

1 Inch = 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters

BOLT TORQUE GRADE5 GRADE 8

THREAD NUMBER THREAD DISTANCE

4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2

BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS

BATTERY TEST PROCEDURES . . . . . . . . . . . . . 2 GENERATOR T E S T PROCEDURES ON

Fig. 2 Charging System Components

All OBD sensing systems are monitored by the

BATTERY TEST PROCEDURES

GENERAL INFORMATION Completely discharged batteries may take sev­

• Divide the result above by 10. 12.2 50%

(2) Connect a suitable Volt-Ammeter-Load tester

Fig. 6 Remove Surface Charge from Battery

Fig. 7 Load 50% Cold Crank Rating Note Voltage

Fig. 5 Volt-Ammeter-Load Tester Connections LOAD TEST TEMPERATURE

(3) Battery chargers vary in the amount of voltage

13.9 volts or less up to 16 hrs.

BATTERY DIAGNOSTICS CHART

r STARTER WON'T CRANK VISUAL INSPECTION

GENERAL INFORMATION Completely discharged batteries may take sev

Testing procedures for these components are as fol

PREPARATI01 (8) Connect an engine tachometer and connect neg

CAUTION: It i s imperative that the cables are con

CAUTION: Do not connect the starter motor incor

CAUTION: Never force a belt over a pulley rim u s